1996 Dodge Ram Service Manual PDF

9
SERVICE
MANUAL
RAM TRUCK
1500 - 3500
2 WHEEL DRIVE
4 WHEEL DRIVE
VOL.1 00-08
9
SERVICE
MANUAL
RAM TRUCK
1500 - 3500
2 WHEEL DRIVE
4 WHEEL DRIVE
VOL.2 09-25
CHRYSLER
CORPORATION
SERVICE MANUAL
1996
RAM T R U C K
1500 - 3500
To order the special service tools used and

illustrated, please refer to the instructions on
inside back cover.
^CHRYSLER
mSf C O R P O R A T I O N
NO PART OF THIS PUBLICATION MAY BE

REPRODUCED, STORED IN A RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY FORM OR
BY ANY MEANS, ELECTRONIC, MECHANICAL,
PHOTOCOPYING, RECORDING, OR OTHERWISE,
WITHOUT THE PRIOR WRITTEN PERMISSION
OF CHRYSLER CORPORATION.
Chrysler Corporation reserves the right to make changes in design or to

make additions to or improvements in its products without imposing any obli
gations upon itself to install them on its products previously manufactured.
Litho in U.S.A. Copyright © 1995 Chrysler Corporation 20M0995

FOREWORD
The information contained in this service manual has been prepared for the professional automotive tech
nician involved in daily repair operations. This manual does not cover theory of operation, which is addressed
in service training material. Information describing the operation and use of standard and optional equipment
is included in the Owner's Manual provided with the vehicle.
Information in this manual is divided into groups. These groups contain general information, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and compo
nents. To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar
after the group title is aligned to a solid tab on the first page of each group. The first page of the group has
a contents section that lists major topics within the group. I f you are not sure which Group contains the infor
mation you need, look up the Component/System in the alphabetical index located in the rear of this manual.
A Service Manual Comment form is included at the rear of this manual. Use the form to provide Chrysler
Corporation with your comments and suggestions.
Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When
replacing fasteners, always use the same type (part number) fastener as removed.
Chrysler Corporation reserves the right to change testing procedures, specifications, diagnosis, repair
methods, or vehicle wiring at any time without prior notice or incurring obligation.
GROUP TAB LOCATOR
Introduction life!
Lubrication and Maintenance
2 Suspension
Differential and Driveline
Brakes
Clutch
7 Cooling System
8A Battery
8B Starting Systems
8C Charging System
8D Ignition System
8E Instrument Panel Systems
8F Audio Systems
8G Horn Systems
8H Vehicle Speed Control System
8J Turn Signal and Hazard Warning Systems
8K Wiper and Washer Systems
8L Lamps
8M Passive Restraint Systems
8P Power Door Locks
8R Power Seat Systems
8S Power Window Systems
8T Power Mirror Systems
8U Chime/Buzzer Warning Systems
8V Overhead Console Systems
8W Wiring Diagrams
Q Engine
j 1 Exhaust System and Intake Manifold
j 3 Frame and Bumpers
14 Fuel System
j 9 Steering
21 Transmission and Transfer Case
22 Tires and Wheels Hi
23 Body
24 Heating and Air Conditioning
25 Emission Control Systems
Component and System Index
Service Manual Comment Forms (Rear of Manual)

BR INTRODUCTION 1
INTRODUCTION
CONTENTS
page page
GENERAL INFORMATION DISPLAY SYMBOLS 3

BODY CODE PLATE . 2 METRIC SYSTEM 10
EQUIPMENT IDENTIFICATION PLATE . . . . . . . . . 3 VEHICLE DIMENSIONS 3
FASTENER IDENTIFICATION 7 VEHICLE IDENTIFICATION NUMBER . . . . . . . . . 1
INTERNATIONAL VEHICLE CONTROL AND VEHICLE SAFETY CERTIFICATION LABEL . . . . . 2
GENERAL INFORMATION To protect the consumer from theft and possible

fraud the manufacturer is required to include a
VEHICLE IDENTIFICATION NUMBER Check Digit at the ninth position of the Vehicle Iden
The Vehicle Identification Number (VIN) plate is tification Number. The check digit is used by the
located on the lower windshield fence near the left manufacturer and government agencies to verify the
A-pillar (Fig. 1). The V I N contains 17 characters that authenticity of the vehicle and official documenta
provide data concerning the vehicle. Refer to the V I N tion. The formula to use the check digit is not
decoding chart to determine the identification of a released to the general public.
vehicle.
The Vehicle Identification Number is also
imprinted on the:
• Body Code Plate.
® Equipment Identification Plate.
• Vehicle Safety Certification Label.
• Frame rail.
Fig. 1 Vehicle Identification Number (VIN) Location

INTRODUCTION BR
G E N E R A L INFORMATION (Continued)
POSITION INTERPRETATION CODE = D E S C R I P T I O N

1 Country of Origin 1 = United States
3 = Mexico
2 Make B = ôdge
3 Vehicle Type 4 = Multipurpose Passenger
5 = Bus
6 = Incomplete
7 = Truck
4 Gross Vehicle Weight Rating H = 6001-7000
J = 7001-8000
K = 8001-9000
L = 9001-10,000
M = 10,001-14,000
W = Hydraulic Brakes
5 Vehicle Line C = Ram Cab Chassis/Ram Pick Up (4x2)
F = Ram Cab Chassis/Ram Pick Up (4x4)
6 Series 1 = 1500
2 = 2500
3 = 3500
7 Body Style 3 = Club Cab
6 = Conventional Cab Cab Chassis
8 Engine C = 5.9L 6cyl. Diesel
W = 8.0L 10 cyl. MPI
X = 3.9L 6 cyl. MPI
Y = 5.2L 8 cyl. MPI
Z = 5.9L 8 cyl. MPI-LDC
5 = 5.9L 8cyl. MPI-HDC
9 Check Digit
10 Model Year T = 1996
11 Plant Location J = St. Louis North
S = Dodge City
G = Saltillo
M = Lago Alberto Assembly
12 thru 17 Vehicle Build Sequence
VEHICLE SAFETY CERTIFICATION LABEL BODY CODE PLATE

A certification label is attached to the left side The Body Code Plate is located on the floor pan
B-pillar (Fig. 2). The label certifies that the vehicle under the passenger seat (Fig. 3). There can be a
conforms to Federal Motor Vehicle Safety Standards maximum of seven rows of vehicle information
(FMVSS). The label also lists the: imprinted on the plate. The information should be
• Month and year of vehicle manufacture. read from left to right, starting with line 1 at the
• Gross Vehicle Weight Rating (GVWR). The gross bottom of the plate up through line 7 (as applicable)
front and rear axle weight ratings (GAWR's) are at the top of the code plate.
based on a minimum rim size and maximum cold tire Refer to the decoding chart to decode lines 1 up
inflation pressure. through 3.
• Vehicle Identification Number (VIN). Lines 4 through 7 (if used) on the vehicle code
• Type of vehicle. plate are imprinted on the plate (in sequence) accord
• Type of rear wheels. ing to the following:
• Bar code. • 3-character sales code.
• Paint Code.
• Month, Day and Hour (MDH) of final assembly.
BR INTRODUCTION 3
G E N E R A L I N F O R M A T I O N (Continued)
CHRYSLER DATE OF m I f there is not enough space left in the row for all
flFD BY of the 6-digit SEC code (if used):
CORPORATION MM 88488 LB 2903 KG
GP
tfR FRONT U1IH TR
I ES RMIS ft? PSI COO • The unused space will remain blank.
3309 LB 149? KG P235/75R15KL 15 X GiHD 35 • The code will be listed in the next row.
m m WTIH !!KS MS ft! PSI COLD The last nine positions of row 7 will contain a
3850 LB 1747 KG P235/75R15XL 15 X BiHD 41 2-digit code, when applicable, and a 6-digit gateline
THIS UEHC
I LE COHFOPS lt !0 ALL APPLC
I ABLE FEDERAOR UEH J CLE WW
TL serial number (same as the last 6 numbers of the
I EFFECI OH THE DATE OF I yn ABOVE. VIN).
II II!I I I I I TVPE: TRUCK The last code imprinted on a vehicle code plate will
xxxxxx SINGLE X DOHL
be followed by the imprinted word END. When two
vehicle code plates are required, the last available
spaces on the first plate will be imprinted with the
)H: l i U l i HI PftIHT:PUS UEH ICLE HADE IN TIM« 4G4B<* 5 letters CTD (for continued).
8020cd69
When a second vehicle code plate is necessary, the
first four spaces on each row will not be used because
Fig. 2 Vehicle Safety Certification Label—Typical
of the plate overlap.
PRIMARY SECONDARY VINYL ROOF
PAINT PAINT CODE EQUIPMENT IDENTIFICATION PLATE
I
The Equipment Identification Plate (Fig. 4) is
located at the left, front of the inner hood panel. The
VEHICLE plate lists information concerning the vehicle as fol
VEHICLE MODEL lows:
ORDER- -NUMBER
NUMBER • The model.
ENGINE • The wheelbase.
(3) XXX > XXXXX)X XXX xxxxxx -CODE
PAINT- • The VIN (Vehicle Identification Number).
PROCEDURE (2) XXX xxxx xxxx xxxx XXX
-INTERIOR • The T.O.N, (order number).
0) XXX X XXXXXXXXXXXXXXXXX TRIM CODE • The optional and special equipment installed on
the vehicle.
TRANSMISSION VEHICLE IDENTIFICATION Refer to the information listed on the plate when
CODE J NUMBER
MARKET U-C-B-M
ordering replacement parts.
CODE 90IN-3
r
Qmmsi EQUIPMENT !Dem¥iE^
Fig. 3 Body Code Plate
BODY CODE DECODING MODELS V.I.N. \ ^ . \ .
CODE N O . DESCRIPTION CODE N O . DESCRIPTION
Line #1 D i g i t 1-3 Transmission Sales Code
Digit 4 Open Space
Digit 5 Market Code - U-C-B-M
Digit 6 Open Space
Digit 7-23 Vehicle I d e n t i f i c a t i o n No.
Line #2 D i g i t 1-3 Paint Procedure —u
Digit 4 Open Space
Digit 5-8 Primary Paint
Digit 9 Open Space
Digit 10-13 Secondary Paint Fig. 4 Equipment Identification Plate
Digit 14 Open Space
Digit 15-18 Trim Code VEHICLE DIMENSIONS
Digit 19 Open Space The Vehicle Dimension charts provides the dimen
Digit 20-22 Engine Sales Code
Digit 23 Open Space sions for each type of Ram truck.
Line #3 D i g i t 1-12 Vehicle Order Number INTERNATIONAL VEHICLE CONTROL AND DISPLAY
D i g i t 13 Open Space
D i g i t 14-16 Vinyl Roof Code CDoor Combo SYMBOLS
Code - P i l l e t t e ) The graphic symbols illustrated in the following
D i g i t 17 Open Space
D i g i t 18-23 Model chart are used to identify various instrument con
J901N-20
trols. The symbols correspond to the controls and dis
plays that are located on the instrument panel.
• 3-digit numerical code.
• 6-digit SEC code.
4 INTRODUCTION
vehicle exterior dimensions—STD cab
2500/ 3500/
1500/ 3500 4x4
A Wheelbase 1500 4x4135"
1 19" 135" 135"
e Box Length (feet) 6.5 8.0 8.0
€ Ground Clearance (Empty)
—Front 9.7/8.1 10.0/8.1 10.1/8.1 7 7/'. 1 2
—Rear 10.1/9.8 ! 1 0 . 1 7 9 J ! 10.1/9.3 7 1 ..77
D Overall Length
—Without rear bumper 199.9 220.1 220.1 220.1
—With rear bumper 204.1 224.3 224.3 224.3
1 Overall Height (Empty) 7 2 . 1 / 7 5 . 9 72.1/75.9
1
73.7/78.0 7777:7
¥ Overall Width
—At Front Wheel Lip 70.4 79.4 79.4 79.5 1
8 Track
—Front 68.5 68,5 68.6 63.6
—Rear 68.0 68.0 73.0
H Tailgate Load Height 3 7 2 / 3 5 . 6 31.5/35.6 31.5/35.6 31.4/35.6
i Overhang—Front 37.9 3 ^ 37.9 37.9
J Overhang—Rear
—Without Rear Bumper 47.6 47.6 47.6 47.6
—With Rear Bumper 51.7 51.7 5 77
f€ Back Of Cab To r 51.7
Rear Bumper 87.2 107.4 107.4 77,-
I Front Bumper To
Back O f Cab " \ \v 116.9 116.9 116.9
Approach Angle (Degrees} 25.3/29 7 25.3/29.7 25.3/29.7 "25.3/29.7 1 1
M Breakover Angle (Degrees] : 7.8/2 7 0 I 17.8/21.0 7-' •; :

0 Departure Angle (Degrees) 1 0 7 6 / 3 5 . 2 ^ 3 0 ^ 5 6 . 2 3 0 . 6 / 3 o . 2 ~ 30.6/36.2
1
1
93.5 at cargo box.
J941N-25
VEHICLE EXTERIOR DIMENSIONS—CLUE CAB
1500/ 2500/ 3500/

15004x4 25004x4 3500 4x4
A Wheelbase 139" 155" 139" 155" 155"
1 Box Length (Feet) 6.5 8.0 8.0 6.5 8.0
C Ground Clearance—(Empty)
—Front 87/8.5 8.6/8.5 9.9/9.0 9.8/9.1 9.8/8.1
—Rear 7.5/7.7 7.5/7.7 8.6 8.6 8.6
D Overall Length
—Without rear bumper 220.1 240.1 220.1 240.1 240.1
—With rear bumper 224.0 244.0 224.0 244.0 244.0
E Overall Height (Empty) 71.6/74.6 7).5/74.5 72.9/77.2 72.8/77.1 72.8/77.2
f Overall Width Of Cab 79.4 79.4 79.4 79.4 79.4
G Track
—?rorii 66.9/68.5 66.9/68.5 68.6/68.9 68.6/68.9 69.8
—Rear 66.9 667 68 0 68.0 73.0
H Tailgate Load Height 31.3/33.9 31 3/34.4 34.4/37.3 33.3/37.2 33.8/37.8
I Overhang—Front 37.9 37.9 37.9 37.9 37.9
J Overhang;—Rear
—Without rear bumper .a.s 47.5 A7.5 43.5 5
—With rear bumper 475 51.5 51.5 47.5 51.5
K Back of Cab To Rear Bumper 87.1 107.1 ! 107.1 87.1 ' 107.1
L Front Bumper To Back Of Cab 136.9 136.9 •; 36.9 136.9 136/'
M Approach Angle (Degrees) 25.1/30.6 25.2/30.6 .267/33.7 26.8/33.8 26.3/33/
N Breakover Angle (Degrees) 16.7/18.4 15.8/17.1 19.2/23.0 18.1/21.3 18.0/2i/i
0 Depariure Angle (Degrees) 23.8/26.9 21.8/247 26.0/31.0 24.1/28.4 24.6/28.9
(1) 93.3 at cargo box with dual-rear wheels.
Note: All dimensions in inches unless otherwise noted.
J95IN-26
6 INTRODUCTION — BR
VEHICLE EXTERIOR DIMENSIONS—CHASSIS C A B
EXTERIOR
4x2 Models 4x4 models
Model mm 35§§ 2500 3500 3500
HD mw mw HD DRW mw
A Wheelbase 135 139 163 135 139 163
i Cab To Axle 55.7 59.7 83.7 55.7 59.7 83.7
C Overall Length 216.7 220.7 244.7 216.7 220.7 244.7
D Overall Height (Empty) 72.4 77.3 77.1 75.9 77.2 77.1
E Overall Width . 79.4 94.6 94.6 79.4 94.6 94.6
F Track
—Front 68.6 69.8 69.8 68.9 69.8 69.8
—Rear 68.0 73.0 73.0 68.0 73.0 73.0
G Rear Track, Inside 58.0 51.4 51.4 58.0 51.4 51.4
H Rear Track, Outside 78.0 94.6 94.6 78.0 94.6 94.6
1 Overhang—Front 37.9 37.9 37.9 37.9 37.9 37.9
J Axle To End Of Frame 44.1 44.1 44.1 44.1 44.1 44.1
K Center Of Front Wheel
To Back Of Cab 79.0 79.0 79.0 79.0 79.0 79.0
L Frame To Top Of Cab 52.9 52.9 52.9 52.9 52.9 52.9
M Top Of Frame To Ground 29.6 34.3 34.1 34.0 34.3 34.2
N Inside Width Between
Frame Rails 31.7 31.7 31.7 31.7 31.7 31.7
/ n n anr/3HD n n \
O Outside Width Between
Frame Rails 37.6 37.6 37.6 37.6 37.6 37.6
P Front Bumper To Back
Of Cab 116.9 116.9 116.9 116.9 116.9 116.9
Q Front Of Dash To
lack Of Cab NA NA NA NA NA NA
R Ground Clearance
—Front 10.1 15.2 15.2 8.1 8.6 8.6
—Rear 8.5 9.0 9.0 8.4 9.0 9.0
NOTE: A l l dimensions are ininches unless noted.
DRW = Dual-rear wheel.
N A = N o t available at time of printing.
J94IN-27
BR — — — • • • • • — • • INTRODUCTION 7
I N T E R N A T I O N A L C O N T R O L A N D DISPLAY SYMBOLS
10
HIGH BEAM
$0
FOG UGHTS
*
HEADLIGHTS,
PARKING LIGHTS,
PANEL LIGHTS TURN SIGNAL
A
HAZARD WARNING
WINDSHIELD
WASHER
WINDSHIELD WINDSHIELD WIPER

<W
WINDSCREEN
DEMISTING REAR WINDOW REAR WINDOW
WIPER AND WASHER AND DEFROSTING VENTILATING FAN DEFOGGER WIPER
tD i
B £3
REAR WINDOW ENGINE COOLANT BATTERY CHARGING
WASHER FUEL TEMPERATURE CONDITION ENGINE OIL SEAT BELT
(©) ky > i ... i

REAR HOOD
BRAKE FAILURE PARKING BRAKE FRONT HOOD (TRUNK) HORN UGHTtR
J95IN-23
FASTENER IDENTIFICATION INCH METRIC
THREAD IDENTIFICATION 5/16-18 M8 X 1.25

SAE and metric bolt/nut threads are not the same. THREAD NUMBER THREAD DISTANCE
The difference is described in the Thread Notation MAJOR OF MAJOR BETWEEN
DIAMETER THREADS DIAMETER IN THREADS IN
chart (Fig. 5). PER INCH MILLIMETERS MILLIMETERS
IN INCHES
GRADE/CLASS IDENTIFICATION
The SAE bolt strength grades range from grade 2 PR606B
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the Fig. 5 Thread Notation—SAE and Metric
line marks on the top of each bolt head. The actual
the greater the bolt strength. Some metric nuts are
bolt strength grade corresponds to the number of line
imprinted with a single-digit strength class on the
marks plus 2. The most commonly used metric bolt
nut face. Refer to the Fastener Identification and
strength classes are 9.8 and 12.9. The metric
Fastener Strength Charts.
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
8 INTRODUCTION _
GENERAL INFORMATION (Continued)
FASTENER IDENTIFICATION
bolt Markings and Torque - Metric
Commercial Steel Class

8.8 10.9 12.9
Body
Size Torque Torque Torque
Diam. Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum
mm N»m ft-lb ft-lb ft-lb N®m ft-lb ft-lb N»m ft-lb
6 9 5 7 4 14 9 11 7 14 9 11 7
7 14 9 11 7 18 14 14 11 23 18 18 14
8 25 18 18 14 32 23 25 18 36 27 28 21
10 40 30 30 25 60 45 45 35 70 50 55 40
12 70 55 55 40 105 75 80 60 125 95 100 75
14 115 85 90 65 160 120 125 95 195 145 150 110
16 180 130 140 100 240 175 190 135 290 210 220 165
18 230 170 180 135 320 240 250 185 400 290 310 230
Bolt Markings and Torque Values - U.S. Customary
SAE Grade Number 5 8
Bolt Head Markings

These are all SAE Grade 5 (3) line
Bolt Torque - Grade 5 Bolt Bolt Torque - Grade 8 Bolt

Body Size Cast Iron Al uminum Cast Iron Aluminum
ft-lb N®m 1Mb ft-lb ft-lb
1/4 -20 9 7 8 6 15 11 12 9
- 28 12 9 9 7 18 13 14 10
5/16 - 18 20 15 16 12 30 22 24 18
- 24 23 17 19 14 33 24 25 19
3/8 - 16 40 30 25 20 55 40 40 30
- 24 40 30 35 25 60 45 45 35
7/16 - 14 60 45 45 35 90 65 65 50
-20 65 50 55 40 95 70 75 55
1/2 - 13 95 70 75 55 130 95 100 75
-20 100 75 80 60 150 110 120 90
9/16 - 12 135 100 110 80 190 140 150 110
- 18 150 110 115 85 210 155 170 125
5/8-11 180 135 150 no 255 190 205 150
- 18 210 155 160 120 290 215 230 170
3/4 - 10 325 240 255 190 460 340 365 270
- 16 365 270 285 210 515 380 410 300
7/8 -9 490 360 380 280 745 550 600 440
- 14 530 390 420 310 825 610 660 490
1 -8 720 530 570 420 1100 820 890 660
- 14 800 590 650 480 1200 890 960 710
95IN-6
BR INTRODUCTION 9
FASTENER STRENGTH
HOW TO DETERMINE BOLT STRENGTH
Mark Class Mark Class
Hexagon A— 4T Stud bolt

head bolt 5— 5T
/ \ Bolt 6 — 6T
jfY^^headNo. 7— No mark
y
7T
8T
9T 4T
lO- 10T
ll — 1 IT
j^^^^j No mark 4T
Hexagon
flange bolt
w / washer
((^^j) No mark 4T Grooved
hexagon bolt
61
Hexagon
head bolt TWO 51
j 1 protruding
lines
Hexagon
flange bolt
T w o
j. 61 Welded bolt
w / washer 1 J protruding
hexagon bolt lines
Hexagon
head bolt f^f% T h r e e
IL? ^ j j protruding 71
lines 41
Hexagon
head bolt F U r
f f ^ l °
|L> J J protruding 8T
lines
95IN-4
10 INTRODUCTION BR
METRIC SYSTEM
Mega (M) Million Deci (D) Tenth
WARNING; USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER Kilo (K) Thousand Centi (C) Hundreth
SONAL INJURY.
Milli (m) Thousandth
Figure art, specifications and torque references in
this Service Manual are identified in metric and SAE J901N-2
format.
Fig, 6 Metric Prefixes
During any maintenance or repair procedures, it is
important to salvage metric fasteners (nuts, bolts, Refer to the Conversion Chart to convert torque
etc.) for reassembly. I f the fastener is not salvage values listed in metric Newton- meters (N-m). Also,
able, a fastener of equivalent specification should be use the chart to convert between millimeters (mm)
used. and inches (in.)
The metric system is based on quantities of one,
ten, one hundred, one thousand and one million (Fig.
6).
The following chart will assist in converting metric
units to equivalent English and SAE units, or vise
versa.
CONVERSION FORMULAS AND EQUIVALENT VALUES
Multiply By ToGaf Multiply By To Get

in-lbs x 0.11298 Newton-Meters (N*m) x 8.851 = in-lbs
ft-lbs x 1.3558 Newton-Meters (N*m) N*m x 0.7376 = ft-lbs
Inches Hg (60°F) x 3.377 Kilopascafs (kPa) kPa x 0.2961 = Inches Hg

psi x 6.895 = Kilopascals (kPa) kPa x 0.145 - psi
Inches x 25.4 Millimeters (mm) mm x 0.03937 = Inches

Feet x 0.3048 Meters (M) M x 3.281 = Feet
Yards x 0.9144 Meters (M) M x 1.0936 = Yards
Miles x 1.6093 = Kilometers (Km) Km x 0.6214 = Miles
mph x 1.6093 ss Kilometers/Hr. (Km/h) Km/h x 0.6214 = mph

Feet/Sec. x 0.3048 ss Meters/Sec. (M/S) M/S x 3.281 = Feet/Sec.
Kilometers/Hr. x 0.27778 SB Meters/Sec. (M/S) M/S x 3.600 = Kilometers/Hr.
mph x 0.4470 = Meters/Sec. (M/S) M/S x 2.237 s mph
COMMON METRIC EQUIVALENTS

1 Inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters
1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile =1.6 Kilometers
J91IN-1
BR — — — _ _ _ _ _ INTRODUCTION 11
METRIC CONVERSION
in-lbs to N»m N»m to in-lbs

i n - lb N«m in-lb N®m in-lb N»m in-lb N®m in-lb N®m 0
N m in-lb N©m in-lb N®m in-lb N®m in-lb N°m in-lb
2 .2260 42 4.7453 82 9.2646 122 13.7839 162 18.3032 .2 1.7702 4.2 37.1747 8.2 72.5792 12.2 107.9837 16.2 143.3882
.4 3.5404 4.4 38.9449 8.4 74.3494 12.4 109.7539 16.4 145.1584
4 .4519 44 4.9713 84 9.4906 124 14.0099 164 18.5292
.6 5.3107 4.6 40.7152 8.6 76.1197 12.6 111.5242 16.6 146.9287
6 .6779 46 5.1972 86 9.7165 126 14.2359 166 18.7552
8 .9039 48 5.4232 88 9.9425 128 14.4618 168 18.9811 .8 7.0809 4.8 42.4854 8.8 77.8899 12.8 113.2944 16.8 148.6989
10 1.1298 50 5.6492 90 10.1685 130 14.6878 170 19.2071 1 8.8511 5 44.2556 9 79.6601 13 115.0646 17 150.4691
12 1.3558 52 5.8751 92 10.3944 132 14.9138 172 19.4331 1.2 10.6213 5.2 46.0258 9.2 81.4303 13.2 116.8348 17.2 152.2393
14 1.5818 54 6.1011 94 10.6204 134 15.1397 174 19.6590 1.4 12.3916 5.4 47.7961 9.4 83.2006 13.4 118.6051 17.4 154.0096
16 1.8077 56 6.3270 96 10.8464 136 15.3657 176 19.8850 1.6 14.1618 5.6 49.5663 9.6 84.9708 13.6 120.3753 17.6 155.7798
18 2.0337 58 6.5530 98 11.0723 138 15.5917 178 20.1110 1.8 15.9320 5.8 51.3365 9.8 86.7410 13.8 122.1455 17.8 157.5500
20 2.2597 60 6.7790 100 11.2983 140 15.8176 180 20.3369 2 17.7022 6 53.1067 10 88.5112 14 123.9157 18 159.3202
22 2.4856 62 7.0049 102 11.5243 142 16.0436 182 20.5629 2.2 19.4725 6.2 54.8770 10.2 90.2815 14.2 125.6860 18.5 163.7458
24 2.7116 64 7.2309 104 11.7502 144 16.2696 184 20.7889 2.4 21.2427 6.4 56.6472 10.4 92.0517 14.4 127.4562 19 168.1714
26 2.9376 66 7.4569 106 11.9762 146 16.4955 186 21.0148 2.6 23.0129 6.6 58.4174 10.6 93.8219 14.6 129.2264 19.5 172.5970
28 3.1635 68 7.6828 108 12.2022 148 16.7215 188 21.2408 2.8 24.7831 6.8 60.1876 10.8 95.5921 14.8 130.9966 20 177.0225
30 3.3895 70 7.9088 110 12.4281 150 16.9475 190 21.4668 3 26.5534 7 61.9579 11 97.3624 15 132.7669 20.5 181.4480
32 3.6155 72 8.1348 112 12.6541 152 17.1734 192 21.6927 3.2 28.3236 7.2 63.7281 11.2 99.1326 15.2 134.5371 21 185.8736
34 3.8414 74 8.3607 114 12.8801 154 17.3994 194 21.9187 3.4 30.0938 7.4 65.4983 11.4 100.9028 15.4 136.3073 22 194.7247
36 4.0674 76 8.5867 116 13.1060 156 17.6253 196 22.1447 3.6 31.8640 7.6 67.2685 11.6 102.6730 15.6 138.0775 23 203.5759
38 4.2934 78 8.8127 118 13.3320 158 17.8513 198 22.3706 3.8 33.6342 7.8 69.0388 11.8 104.4433 15.8 139.8478 24 212.4270
40 4.5193 80 9.0386 120 13.5580 160 18.0773 200 22.5966 4 35.4045 8 70.80% 12 106.2135 16 141.6180 25 221.2781
ft-lbs to N®m N®m to ft-lbs

ft-lb N©m ft-lb N«m ft-lb N«m ft-lb e
N m ft-lb N®m N»m ft-lb N®m ft-lb N®m ft-lb N«m ft-lb N®m ft-lb
1 1.3558 21 28.4722 41 55.5885 61 82.7049 81 109.8212 1 .7376 21 15.9888 41 30.2400 61 44.9913 81 59.7425
2 2.7116 22 29.8280 42 56.9444 62 84.0607 82 111.1770 2 1.4751 22 16.2264 42 30.9776 62 45.7289 82 60.4801
3 4.0675 23 31.1838 43 58.3002 63 85.4165 83 112.5328 3 2.2127 23 16.9639 43 31.7152 63 46.4664 83 61.2177
4 5.4233 24 32.5396 44 59.6560 64 86.7723 84 113.8888 4 2.9502 24 17.7015 44 32.4527 64 47.2040 84 61.9552
5 6.7791 25 33.8954 45 61.0118 65 88.1281 85 115.2446 5 3.6878 25 18.4391 45 33.1903 65 47.9415 85 62.6928
6 8.1349 26 35.2513 46 62.3676 66 89.4840 86 116.6004 6 4.4254 26 19.1766 46 33.9279 66 48.6791 86 63.4303
7 9.4907 27 36.6071 47 63.7234 67 90.8398 87 117.9562 7 5.1629 27 19.9142 47 34.6654 67 49.4167 87 64.1679
8 10.8465 28 37.9629 48 65.0793 68 92.1956 88 119.3120 8 5.9005 28 20.6517 48 35.4030 68 50.1542 88 64.9545
9 12.2024 29 39.3187 49 66.4351 69 93.5514 89 120.6678 9 6.6381 29 21.3893 49 36.1405 69 50.8918 89 65.6430
10 13.5582 30 40.6745 50 67.7909 70 94.9073 90 122.0236 10 7.3756 30 22.1269 50 36.8781 70 51.6293 90 65.38%
11 14.9140 31 42.0304 51 69.1467 71 96.2631 91 123.3794 11 8.1132 31 22.8644 51 37.6157 71 52.3669 91 67.1181
12 16.2698 32 43.3862 52 70.5025 72 97.6189 92 124.7352 12 8.8507 32 23.6020 52 38.3532 72 53.1045 92 67.8557
13 17.6256 33 44.7420 53 71.8583 73 98.9747 93 126.0910 .13 9.5883 33 24.3395 53 39.0908 73 53.8420 93 68.5933
14 18.9815 34 46.0978 54 73.2142 74 100.3316 94 127.4468 14 10.3259 34 25.0771 54 39.8284 74 54.5720 94 69.3308
15 20.3373 35 47.4536 55 74.5700 75 101.6862 95 128.8026 15 11.0634 35 25.8147 55 40.5659 75 55.3172 95 70.0684
16 21.6931 36 48.8094 56 75.9258 76 103.0422 96 130.1586 16 11.8010 36 26.5522 56 41.3035 76 56.0547 96 70.8060
17 23.0489 37 50.1653 57 77.2816 77 104.3980 97 131.5144 17 12.5386 37 27.2898 57 42.0410 77 56.7923 97 71.5435
18 24.4047 38 51.5211 58 78.6374 78 105.7538 98 132.8702 18 13.2761 38 28.0274 58 42.7786 78 57.5298 98 72.2811
19 25.7605 39 52.8769 59 79.9933 79 107.1196 99 134.2260 19 14.0137 39 28.7649 59 43.5162 79 58.2674 99 73.0187
20 27.1164 40 54.2327 60 81.3491 80 106.4654 100 135.5820 20 14.7512 40 29.5025 60 44.2537 80 59.0050 100 73.7562
in. to m m mm to in.
in. mm in. mm in. mm in. mm in. mm mm in. mm in. mm in. mm in. mm in.
.01 .254 .21 5.334 .41 10.414 .61 15.494 .81 20.574 .01 .00039 .21 .00827 .41 .01614 .61 .02402 .81 .03189
.22 .00866 .42 .01654 .62 .02441
.02 .508 .22 5.588 .42 10.668 .62 15.748 .82 20.828 .02 .00079
.23 .00906 .43 .01693 .63 .02480
.82 .03228
.03 .762 .23 5.842 .43 10.922 .63 16.002 .83 21.082 .03 .00118 .83 .03268
.04 1.016 .24 6.096 .44 11.176 .64 16.256 .84 21.336 .04 .00157 .24 .00945 .44 .01732 .64 .02520 .84 .03307
.05 1.270 .25 6.350 .45 11.430 .65 16.510 .85 21.590 .05 .00197 .25 .00984 .45 .01772 .65 .02559 .85 .03346
.06 1.524 .26 6.604 .46 11.684 .66 16.764 .86 21.844 .06 .00236 .26 .01024 .46 .01811 .66 .02598 .86 .03386
.07 1.778 .27 6.858 .47 11.938 .67 17.018 .87 22.098 .07 .00276 .27 .01063 .47 .01850 .67 .02638 .87 .03425
.08 2.032 .28 7.112 .48 12.192 .68 17.272 .88 22.352 .08 .00315 .28 .01102 .48 .01890 .68 .02677 .88 .03465
.09 2.286 .29 7.366 .49 12.446 .69 17.526 .89 22.606 .09 .00354 .29 .01142 .49 .01929 .69 .02717 .89 .03504
.10 2.540 .30 7.620 .50 12.700 .70 17.780 .90 22.860 .10 .00394 .30 .01181 .50 .01969 .70 .02756 .90 .03543
.11 2.794 .31 7.874 .51 12.954 .71 18.034 .91 23.114 .11 .00433 .31 .01220 .51 .02008 .71 .02795 .91 .03583
.12 3.048 .32 8.128 .52 13.208 .72 18.288 .92 23.368 .12 .00472 .32 .01260 .52 .02047 .72 .02835 .92 .03622
.13 3.302 .33 8.382 .53 13.462 .73 18.542 .93 23.622 .13 .00512 .33 .01299 .53 .02087 .73 .02874 .93 .03661
.14 3.556 .34 8.636 .54 13.716 .74 18.796 .94 23.876 .14 .00551 .34 .01339 .54 .02126 .74 .02913 .94 .03701
.15 3.810 .35 8.890 .55 13.970 .75 19.050 .95 24.130 .15 .00591 .35 .01378 .55 .02165 .75 .02953 .95 .03740
.16 4.064 .36 9.144 .56 14.224 .76 19.304 .96 24.384 .16 .00630 .36 .01417 .56 .02205 .76 .02992 .96 .03780
.17 3.318 .37 9.3% .57 14.478 .77 19.558 .97 24.638 .17 .00669 .37 .01457 .57 .02244 .77 .03032 .97 .03819
.18 4.572 .38 9.652 .58 14.732 .78 19.812 .98 24.892 .18 .00709 .38 .01496 .58 .02283 .78 .03071 .98 .03858
.19 4.826 .39 9.906 .59 14.986 .79 20.066 .99 25.146 .19 .0)748 .39 .01535 .59 .02323 .79 .03110 .99 .03898
.20 5.080 .40 10.160 .60 15.240 .80 20.320 1.00 25.400 .20 .00787 .40 .01575 .60 .02362 .80 .03150 1.00 .03937
J901N-10
BR LUBRICATION AND MAINTENANCE 0 -1
LUBRICATION AND MAINTENANCE

CONTENTS
page page
GENERAL INFORMATION 1 MAINTENANCE SCHEDULES—LIGHT DUTY

JUMP STARTING, TOWING AND HOISTING . . . 2 1 VEHICLES 4
MAINTENANCE SCHEDULES—DIESEL ENGINE MAINTENANCE SCHEDULES—MEDIUM DUTY
VEHICLES 17 VEHICLES 8
MAINTENANCE SCHEDULES—HEAVY DUTY
VEHICLES 12
G E N E R A L INFORMATION
INDEX
page page
GENERAL INFORMATION INTERNATIONAL SYMBOLS 1

CLASSIFICATION OF LUBRICANTS 2 INTRODUCTION 1
FLUID CAPACITIES 2 PARTS AND LUBRICANT RECOMMENDATIONS . . . 1
GENERAL INFORMATION best engineered products for servicing Chrysler Cor

poration vehicles.
INTRODUCTION
Service and maintenance procedures for compo INTERNATIONAL SYMBOLS
nents and systems listed in Schedule—A or B can be Chrysler Corporation uses international symbols to
found by using the Group Tab Locator index at the identify engine compartment lubricant and fluid
front of this manual. I f it is not clear which group inspection and fill locations (Fig. 1).
contains the information needed, refer to the index at
the back of this manual. ^ \
There are two maintenance schedules that show
proper service based on the conditions that the vehi
€ » C H R Y S L E R CORPORATION
cle is subjected to.
Schedule—A, lists scheduled maintenance to be
performed when the vehicle is used for general trans
ENGINE OIL
o BRAKE FLUID
portation.
AUTOMATIC POWER
Schedule—B, lists maintenance intervals for vehi
cles that are operated under the conditions listed at
the beginning of the Maintenance Schedule section.
Use the schedule that best describes your driving
G TRANSMISSION
FLUID © STEERING
FLUID
conditions.
Where time and mileage are listed, follow the b ENGINE
COOLANT
WINDSHIELD
WASHER F L U I D y
interval that occurs first.
9500-1
PARTS AND LUBRICANT RECOMMENDATIONS Fig. 1 international Symbols

When service is required, Chrysler Corporation
recommends that only Mopar* brand parts, lubri
cants and chemicals be used. Mopar provides the
0-2 LUBRICATION AND MAINTENANCE BR
CLASSIFICATION OF LUBRICANTS progress to guttering and valve burning. A maximum

Only lubricants that are endorsed by the following sulfated ash content of 1.85 mass % is recommended
organization should be used to service a Chrysler for all oil used in the engine.
Corporation vehicle. Refer to Group 9, Engine for diesel engine oil spec
• Society of Automotive Engineers (SAE) ification.
• American Petroleum Institute (API) (Fig. 2)
• National Lubricating Grease Institute (NLGI) GEAR LUBRICANTS
(Fig. 3 ) SAE ratings also apply to multiple grade gear
lubricants. In addition, API classification defines the
lubricants usage.
LUBRICANTS AND GREASES

Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 3) on the label. At the bottom NLGI
symbol is the usage and quality identification letters.
Wheel bearing lubricant is identified by the letter
"G". Chassis lubricant is identified by the latter "L".
9400-9 The letter following the usage letter indicates the
quality of the lubricant. The following symbols indi
Fig. 2 API Symbol cate the highest quality.
GASOLINE ENGINE OIL t NATO
I NAL LUBRC I ATN
IG
GREASE INSTITUTE
SAE GRADE RATING INDICATES ENGINE OIL VISCOSITY NLGI NLGI NLGI
AUTOMOTV IE AUTOMOTV IE AUTOMOTV IE
An SAE viscosity grade is used to specify the vis WHEEL BEARNI G & CHASSS
I WHEEL BEARNI G & CHASSS
I WHEEL BEARNI G & CHASSS
I
LUBRC
I ANT LUBRC
I ANT LUBRC
I ANT
cosity of engine oil. SAE 30 specifies a single viscos
GC Li GC-LB
ity engine oil. Engine oils also have multiple
viscosities. These are specified with a dual SAE vis WHEEL CHASSIS CHASSIS AND
cosity grade which indicates the cold-to-hot tempera BEARINGS LUBRICATION WHEEL BEARINGS
ture viscosity range. 9200-7
• SAE 30 = single grade engine oil.
• SAE 10W-30 = multiple grade engine oil. Fig. 3 NLGI Symbol
FLUID CAPACITIES
API QUALITY CLASSIFICATION
The API Service Grade specifies the type of perfor FUEL TANK
mance the engine oil is intended to provide. The API
Service Grade specifications also apply to energy con 119 inch wheel base . .98 L (26 gal.)
serving engine oils. 135 inch wheel base . .98 L (26 gal.)
Use engine oil that is API Service Grade Certified All others 132 L (35 gal.)
or an oil that conforms to the API Service Grade SH
or SH/CD. MOPAR engine oils conform to all of these ENGINE OIL W/FILTER CHANGE
service grades.
Refer to Group 9, Engine for gasoline engine oil 3.9L 3.8 L (4.0 qts.)
specification. 5.2L & 5.9L Gasoline 4.7 L (5.0 qts.)
5.9L Diesel 9.5 L (10.0 qts.)
DIESEL ENGINE OIL 8.0 L 6.6 L (7.0 qts.)
ENGINE OIL W/O FILTER CHANGE
ENGINE OIL QUALITY
Use only oils conforming to API Quality CE, or 3.9L. . .3.3 L (3.5 qts.)
CE/SG. A sulfated ash limit is specified for lubrica
5.2L & 5.9L Gasoline .4.3 L (4.5 qts.)
tion oil used in Cummins engines. Oils with a high
5.9L Diesel* .
ash content may produce deposits on valves that can
8.0L*
*Oil filter must be changed with every oil change.
BR - LUBRICATION AND MAINTENANCE 0-3
COOLING SYSTEM POWER TAKE OFF ADAPTER
3.9L. 19 L (20 qts.) N V 0 2 1 . . . . . . . . . . . . . . . . . . . . . . . . .2.1 L (4.6 pts.)

5.2L. . . . . . . . . . . . . . .19 L (20 qts.) FRONT AXLE
5.9L Gas . . . . . . . . . . . . . . . .19 L (20 qts.)
5.9L Diesel .24.5 L (26.0 qts.) Dana 44. .3.2 L (6.8 pts.)
8.0L . . .22.7 L (24.0 qts.) Dana 60 3.6 L (7.6 pts.)
AUTOMATIC TRANSMISSION REAR AXLE
Dry fill capacity*
9-1/4 inch. . . . . . . . . . . . . . . . . . .2.3 L (4.8 pts.)
42RE . . . . . . . . . . . . . . . . 8.0-10.4 L (17-22 pts.) Dana 60 (2WD) . . . . . . . . . . . . . . . . . .3.0 L (6.3 pts.)
46RE .8.2-12.3L (17.5-26 pts.) Dana 60 (4WD) .3.4 L (7.3 pts.)
47RE .8.2-15.6 L (17.5-33 pts.) Dana 70 (2WD) 3.3 L (7.0 pts.)
*Depending on type and size of internal cooler, Dana 70 (4WD) .3.6 L (7.8 pts.)
length and inside diameter of cooler lines, or use of Dana 80 (2WD) .3.2 L (6.8 pts.)
an auxiliary cooler, these figures may vary. Refer to Dana 80 (4WD) .4.8 L (10.1 pts.)
Group 21, Transmission for proper fluid fill proce
dure. REAR AXLE—LIMITED SLIP DIFFERENTIAL
MANUAL TRANSMISSION Dana 60 (2WD) 3.0 L (6.3 pts.*)

Dana 60 (4WD) 3.4 L (7.3 pts.*)
NV3500 .2.0 L (4.2 pts.) Dana 70 (2WD) . . . . . . . . . . . . . . . . .3.3 L (7.0 pts.*)
NV4500 .3.8 L (8.0 pts.) Dana 70 (4WD) . . . . . . . . . . . . . . . . .3.6 L (7.8 pts.*)
TRANSFER CASE Dana 80 (2WD) .3.2 L (6.8 pts.*)
Dana 80 (4WD). . . . . . . . . . . .4.8 L (10.1 pts.**)
NV231 HD. . . . . . . . . . . . . . . . . . . . . .1.2 L (2.5 pts.) * Include 0.2 L (0.4 pts.) friction modifier.
NV241...... 2.7 L (5.0 pts.) ** Include 0.3 L (0.6 pts.) friction modifier.
NV241 HD .3.5 L (6.5 pts.)
POWER STEERING
NV241 HD W/PTO .4.9 L (9.0 pts.)
All 1.3 L (2.7 pts.)
0 4 LUBRICATION AND MAINTENANCE BR
MAINTENANCE S C H E D U L E S — L I G H T DUTY V E H I C L E S
INDEX
page page
GENERAL INFORMATION LIGHT DUTY SCHEDULE—B 5

INTRODUCTION 4 UNSCHEDULED INSPECTION 4
LIGHT DUTY SCHEDULE—A 4
G E N E R A L INFORMATION Once A Month

• Check tire pressure and look for unusual wear
INTRODUCTION or damage.
The following is a list of Maintenance Schedules • Inspect battery and clean and tighten terminals
for Light Duty Cycle vehicles (1500 and 2500 Models as required.
Except 8.0L). • Check fluid levels of coolant reservoir, brake
There are two maintenance schedules that show master cylinder, power steering, and transmission
proper service based on the conditions that the vehi and add as needed.
cle is subjected to. Use the schedule that best • Check all lights and all other electrical items for
describes these conditions. correct operation.
Schedule—A, lists all the scheduled maintenance
to be performed under "normal" operating conditions At Each Oil Change
for Light Duty vehicles. • Inspect exhaust system.
Schedule—B, lists maintenance recommended for • Inspect brake hoses.
Light Duty vehicles operated under the following • Rotate the tires at each oil change interval
conditions: shown on Schedule—A (7,500 Miles) or every other
• Frequent short trip driving less than 5 miles (8 km) interval shown on Schedule—B (6,000 Miles).
• Frequent driving in dusty conditions • Check engine coolant level, hoses, and clamps.
• Frequent trailer towing • If your mileage is less than 7,500 miles (12 000 km)
• Extensive idling yearly, replace the engine oil filter at each oil change.
•, More than 50% of your driving is at sustained • Lubricate steering linkage.
high speeds during hot weather, above 90°F (32°C)
Where time and mileage are listed, follow the LIGHT DUTY SCHEDULE—A
7,500 Miles (12 000 km) or at 6 months
EMISSION CONTROL SYSTEM MAINTENANCE © Change engine oil.
The scheduled emission maintenance listed in bold
type on the Maintenance Schedules, must be done at 15,000 Miles (24 000 km) or at 12 months
the mileage specified to assure the continued proper • Change engine oil.
functioning of the emission control system. These, and • Replace engine oil filter.
all other maintenance services included in this manual,
should be done to provide the best vehicle performance 22,500 Miles (36 000 km) or at 18 months
and reliability. More frequent maintenance may be • Change engine oil.
needed for vehicles in severe operating conditions such • Inspect front wheel bearings. Clean and repack,
as dusty areas and very short trip driving. if required (4x2).
• Inspect brake linings.
UNSCHEDULED INSPECTION
At Each Stop For Fuel • Change engine oil.
• Check engine oil level and add as required. • Change engine oil filter.
• Check windshield washer solvent and add as • Replace engine air cleaner element.
required. • Replace spark plugs.

® Change engine oil.
BR LUBRICATION AND MAINTENANCE I -5
• Drain and, refill automatic transmission fluid. 97,500 Miles (156 000 km) or at 78 months
Replace filter and adjust bands. • Change engine oil.
• Drain and refill transfer case fluid.
45,000 Miles (72 000 km) or at 36 months • Change engine oil.
• Change engine oil. • Replace engine oil filter.
• Replace engine oil filter. • Flush and replace engine coolant i f it has been
• Inspect front wheel bearings. Clean and repack, 30,000 miles (48 000 km) or 24 months since last change.
if required (4x2).
• Inspect brake linings. 112,500 Miles (180 000 km) or at 90 months
• Flush and replace engine coolant at 36 months • Change engine oil.
regardless of mileage. • Inspect front wheel bearings. Clean and repack,
if required (4x2).
52,500 Miles (84 000 km) or at 42 months • Drain and refill automatic transmission fluid.
• Change engine oil. Replace filter and adjust bands.
• Flush and replace engine coolant, i f not done at • Drain and refill transfer case fluid.
36 months. • Inspect brake linings.
• Flush and replace engine coolant if it has been
60,000 Miles (96 000 km) or at 48 months 30,000 miles (48 000 km) or 24 months since last change.
• Change engine oil.
• Replace engine oil filter. 120,000 Miles (192 000 km) or at 96 months
• Replace engine air cleaner element. • Change engine oil.
• Replace ignition cables. • Replace engine oil filter.
• Check PCV valve and replace as necessary.* • Replace engine air cleaner element.
• Replace spark plugs. • Replace ignition cables.
- *This maintenance is recommended by Chrysler to • Check P C V valve and replace as neces
the customer but i t is not required to maintain the sary.*
warranty on the PCV valve. • Replace spark plugs.
*This maintenance is recommended by Chrysler to
67,500 Miles (108 000 km) or at 54 months the customer but i t is not required to maintain war
• Change engine oil. ranty on the PCV valve.
• Inspect front wheel bearings. Clean and repack,
if required (4x2). LIGHT DUTY SCHEDULE—B
3,000 Miles (5 000 km)
75,000 Miles (120 000 km) or at 60 months • Change engine oil.
• Replace engine oil filter. 6,000 Miles (10 000 km)
• Drain and refill automatic transmission fluid. • Change engine oil.
Replace filter and adjust bands. • Replace engine oil filter.
• Flush and replace engine coolant if it has been 9,000 Miles (14 000 km)
30,000 miles (48 000 km) or 24 months since last change. • Change engine oil.
82,500 Miles (132 000 km) or at 66 months 12,000 Miles (19 000 km)
• Change engine oil. • Change engine oil.
• Flush and replace engine coolant if it has been • Replace engine oil filter.
30,000 miles (48 000 km) or 24 months since last change. • Drain and refill automatic transmission fluid.
Replace filter and adjust bands.**
90,000 Miles (144 000 km) or at 72 months • Change rear axle fluid.
• Change engine oil. • Change front axle fluid (4x4).
• Replace engine oil filter. • Inspect brake linings.
• Replace engine air cleaner element.
• Replace spark plugs. 15,000 Miles (24 000 km)
• Inspect front wheel bearings. Clean and repack, • Change engine oil.
if required (4x2 ). • Inspect engine air cleaner element, replace
• Inspect brake linings. as necessary.
0 -1 LUBRICATION AND MAINTENANCE BR
18,000 Mites (29 000 km) 48,000 Miles (77 000 km)
• Replace engine oil filter. • Replace engine oil filter.
• Drain and refill automatic transmission fluid.
21,000 Miles (34 000 km) Replace filter and adjust bands.
• Change engine oil. • Change rear axle fluid.
• Inspect front wheel bearings. Clean and repack, • Change front axle fluid (4x4).
if required (4x2) • Inspect brake linings.
24,000 Miles (38 000 km) 51,000 Miles (82 000 km)
. • Replace engine oil filter. • Flush and replace engine coolant.
Replace filter and adjust bands. 54,000 Miles (86 000 km)
• Change rear axle fluid. • Change engine oil.
• Change front axle fluid (4x4). • Replace engine oil filter.
57,000 Miles (91 000 km)
27,000 Miles (43 000 km) • . Change engine oil.
60,000 Miles (96 000 km)
30,000 Miles (48 000 km) • Change engine oil.
• Replace engine oil filter. ® Replace engine air cleaner element.
• Replace engine air cleaner element. • Replace ignition cables.
• Inspect P C V valve, replace as necessary.* • Inspect P C V valve and replace as neces
• Replace spark plugs. sary.*
*This maintenance is recommended by Chrysler to • Replace spark plugs.
the customer but it is not required to maintain war • Drain and refill automatic transmission fluid.
ranty on the PCV. Replace filter and adjust bands.**
• Change rear axle fluid.
33,000 Miles (53 000 km) • Change front axle fluid (4x4).
® Change engine oil. • Inspect brake linings.
36,000 Miles (58 000 km) the customer but i t is not required to maintain war
• Change engine oil. ranty on the PCV valve.
• Replace engine oil filter.
• Drain and refill automatic transmission fluid. 63,000 Miles (101 000 km)
Replace filter and adjust bands.** • Change engine oil.
• Drain and refill transfer case fluid. • Inspect front wheel bearings. Clean and repack,
© Change rear axle fluid. if required (4x2)
• Change front axle fluid (4x4).
• Inspect brake linings. 66,000 Miles (106 000 km)
39,000 Miles (62 000 km) • Replace engine oil filter.
69,000 Miles (110 000 km)
• Inspect front wheel bearing. Clean and repack, i f ® Change engine oil.
required (4x2). • Replace engine oil filter.
• Change engine oil. • Drain and refill transfer case fluid.
• Inspect engine air cleaner element, replace • Change rear axle fluid.
as necessary. • Change front axle fluid (4x4).
BR LUBRICATION AND MAINTENANCE 0 7
75,000 Miles (120 000 km) • Inspect engine air cleaner element, replace
• Change engine oil. as necessary.
• Inspect engine a i r cleaner element, replace • Inspect front wheel bearings. Clean and repack
as necessary. if required (4x2).
78,000 Miles (125 000 km) 108,000 Miles (173 000 km)
81,000 Miles (130 000 km) Replace filter and adjust bands.**
• Change engine oil. • Drain and refill transfer case fluid.
• Flush and replace engine coolant. • Change rear axle fluid.
84,000 Miles (134 000 km) • Inspect brake linings.
© Change engine oil.
• Drain and refill automatic transmission fluid. • Change engine oil.
Replace filter and adjust bands.** • Flush and replace engine coolant.
• Change front axle fluid (4x4). 114,000 Miles (182 000 km)
• Inspect front wheel bearings. Clean and repack • Change engine oil.
if required (4x2). • Replace engine oil filter.
117,000 Miles (187 000 km)
120,000 Miles (192 000 km)
90,000 Miles (144 000 km) • Check engine oil.
• Change engine oil. ' • Replace engine oil filter.
• Replace engine oil filter. ® Replace engine air cleaner element.
• Replace engine air cleaner element. • Replace ignitions cables.
© Inspect P C V valve, replace as necessary.* ® Check P C V valve and replace as neces
• Replace spark plugs. sary.*
*This maintenance is recommended by Chrysler to • Replace spark plugs.
the customer but i t is not required to maintain war • Drain and refill automatic transmission fluid.
ranty on the PCV valve. Replace filter and adjust bands.
© Change rear axle fluid.
93,000 Miles (149 000 km) ® Change front axle fluid (4x4).
• Change engine oil. • Inspect brake linings.
96,000 Miles (154 000 km) the customer but i t is not required to maintain war
• Change engine oil ranty on the PCV valve.
• Replace engine oil filter. **Off-the-highway operation, trailer towing, snow
• Drain and refill automatic transmission fluid. plowing, or prolonged operation with heavy loading,
Replace filter and adjust bands. especially in hot weather require the more frequent
• Change rear axle fluid. transmission service indicated with a ** in Sched
• Change front axle fluid (4x4). ule—B. Perform these services i f the vehicle is oper
• Inspect brake linings. ated under these conditions. *.
* Inspection and service should also be performed
99,000 Miles (158 000 km) anytime a malfunction is observed or suspected.
102,000 Miles (163 000 km)

0 -8 LUBRICATION AND MAINTENANCE
MAINTENANCE S C H E D U L E S — M E P i y H P U T Y WEHICLE5
INDE1
page page
GENERAL INFORMATION MEDIUM DUTY SCHEDULE—B 9

INTRODUCTION 8 UNSCHEDULED INSPECTION . . . . . . . 8
MEDIUM DUTY SCHEDULE—A . . . . 8
GENERAL IMFORl^-L'^M Once A Month

© Check tire pressure and look for unusual wear
The following is a list of Maintenance Schedules • Inspect battery and clean and tighten terminals
for Medium Duty Cycle vehicles (8.0L 2500 and 3500 as required.
Models •— California Only). • Check fluid levels of coolant reservoir, brake
cle is subjected to. Use the schedule that best • Check all lights and all other electrical Items for
to be performed under normal operating conditions At Each Oil Change
for Medium Duty vehicles. • Inspect exhaust system.
Medium Duty vehicles operated under the following • Rotate the tires at each oil change Interval
• Frequent short trip driving less than 5 miles (8 Interval shown on Schedule—B (6,000 Miles).
km) • Check engine coolant level, hoses, and clamps.
• Frequent driving in dusty conditions • Lubricate steering linkage.
• Frequent trailer towing
• Extensive idling MEDIUM DUTY SCHEDULE—A
• More than 50% of your driving is at sustained
high speeds during hot weather, above 90°F (32°C) 6,000 miles (10 000 km) or at 6 months
Where time and mileage are listed, follow the • Replace engine oil and filter.
EMISSION CONTROL SYSTEM MAINTENANCE • Replace engine oil and filter.
The scheduled emission maintenance listed in bold
type on the Maintenance Schedules, must be done at 18,000 Miles (29 000 km) or at 18 months
the mileage specified to assure the continued proper ® Replace engine oil and filter.
functioning of the emission control system. These, • Inspect brake linings.
and all other maintenance services included in this
manual, should be done to provide the best vehicle 24,000 Miles (38 000 km) or at 24 months
performance and reliability. More frequent mainte • Replace engine oil and filter.
nance may be needed for vehicles in severe operating • Drain and refill automatic transmission fluid.
conditions such as dusty areas and very short trip Replace filter and adjust bands.
driving. • Inspect front wheel bearings. Clean and repack,
if required (4x2).
UNSCHEDULED INSPECTION
At Each Stop For Fuel © Replace engine oil and filter.
• Check engine oil level and add as required. • Replace engine air cleaner element.
• Check windshield washer solvent and add as • Replace spark plugs.
required.
LUBRICATION AND MAINTENANCE 0-9
36,000 Miles (58 000 km) or at 36 months 90,000 Miles (144 000 km) or at 90 months
• Replace engine oil and filter. • Replace engine oil and filter.
« Drain and refill transfer case fluid. • Replace engine air cleaner element.
• Inspect brake linings • Replace spark plugs.
<? Flush and replace engine coolant at 36 months, • Inspect brake linings.
regardless of mileage.
42,000 Miles (67 000 km) or at 42 months • Replace engine oil and filter.
• Replace engine oil and filter. • Drain and refill automatic transmission fluid.
Replace filter and adjust bands.
48,000 Miles (77 000 km) or at 48 months • Inspect front wheel bearings. Clean and repack,
• Replace engine oil and filter. if required (4x2).
Replace filter and adjust bands. 102,000 Miles (163 000 km) or at 102 months
• Inspect front wheel bearings. Clean and repack, • Replace engine oil and filter.
if required (4x2).
• Flush and replace engine coolant i f not done at 108,000 Miles (173 000 km) or at 108 months
36 months. • Replace engine oil and filter.
54,000 Miles (86 000 km) or at 54 months • Inspect brake linings.
• Replace engine oil and filter. • Flush and replace engine coolant i f i t has been
• Inspect brake linings. 30,000 miles (48 000 km) or 24 months since last
change.
• Replace engine oil and filter. 114,000 Miles (183 000 km) or at 114 months
® Replace engine air cleaner element. • Replace engine oil and filter.
® Replace ignition cables.
• Replace spark plugs. 120,000 Miles (192 000 km) or at 120 months
• Replace battery. • Replace engine oil and filter.
• Flush and replace engine coolant i f i t has been © Replace engine air cleaner element.
30,000 miles (48 000 km) or 24 months since last • Replace ignition cables.
change. • Replace spark plugs.
© Drain and refill automatic transmission fluid.
66,000 Miles (106 000 km) or at 66 months Replace filter and adjust bands.
• Replace engine oil and filter.
MEDIUM DUTY SCHEDULE—B
© Replace engine oil and filter, 3,000 Miles (5 000 km)
c Drain and refill automatic transmission fluid. • Replace engine oil and filter.
• Drain and refill transfer case fluid. 6,000 Miles (10 000 km)
if required (4x2).
© Replace engine oil and filter. 12,000 Miles (19 000 km)
© Flush and replace engine coolant i f i t has been • Replace engine oil and filter.
30,000 miles (48 000 km) or 24 months since last • Drain and refill automatic transmission fluid.
change. Replace filter and adjust bands.*
84,000 Miles (134 000 km) or at 84 months • Change front axle fluid (4x4).
• Replace engine oil and filter. • Inspect brake linings.
• Flush and replace engine coolant i f i t has been
30,000 miles (48 000 km) or 24 months since last 15,000 Miles (24 000 km)
change. • Replace engine oil and filter.
0 - 10 LUBRICATION AND MAINTENANCE
18,000 Miles'(29 000 km) 51,000 Miles (82 000 km)

9 Replace engine oil and filter. • Replace engine oil and filter.
21,000 Miles (29 000 km) 54,000 Miles (86 000 km)
24,000 Mites (88 000 km) 57,000 Miles (91 000 km)
• Inspect front wheel bearings. Clean and repack, ® Replace engine oil and filter.
if required (4x2). • Replace engine air cleaner element.
© Change rear axle fluid. » Replace ignition cables.
• Change front axle fluid (4x4). ® Replace spark plugs.
• Inspect brake linings. • Drain and refill automatic transmission fluid.
Replace filter and adjust bands.*
27,000 Miles (43 000 km) • Change rear axle fluid.
• Replace engine oil and filter. © Change front axle fluid (4x4).
30,000 Miles (48 000 km) • Replace battery.
» Replace engine air cleaner element. 63,000 Miles (101 000 km)
• Replace spark plugs. • Replace engine oil and filter.
33,000 Miles (53 000 km) 66,000 Miles (106 000 km)
36,000 Miles (58 000 km) 69,000 Miles (110 000 km)
• Replace engine oil and filter. ® Replace engine oil and filter.
Replace filter and adjust bands.* 72,000 Mites (115 000 km)
• Drain and refill transfer case fluid. © Replace engine oil and filter.
• Change rear axle fluid. ® Drain and refill automatic transmission fluid.
© Change front axle fluid (4x4). Replace filter and adjust bands.
• Inspect brake linings. • Drain and refill transfer case fluid.
39,000 Miles (62 000 km) if required (4x2).
• Replace engine oil and filter. • Change rear axle fluid.
75,000 Miles (120 000 km)
45,000 Miles (72 000 km) • Replace engine oil and filter.
78,000 Miles (125 000 km)
48,000 Miles (77 000 km) • Replace engine oil and filter.
• Replace engine oil and filter. • Flush and replace engine coolant.
if required (4x2).
• Change rear axle fluid. 84,000 Miles (134 000 km)
• Change front axle fluid (4x4). • Replace engine oil and filter.
• Flush and replace engine coolant. Replace filter and adjust bands.*
BR LUBRICATION AND MAINTENANCE 0 - 11
Replace filter and adjust bands.*
87,000 Miles (139 000 km) • Drain and refill transfer case fluid.
• Replace engine oil and filter. • Change rear axle fluid.
• Replace engine oil and filter. • Flush and replace engine coolant.
• Replace engine a i r cleaner element.
® Replace spark plugs, 111,000 Miles (178 000 km)
93,000 Miles (149 000 km)
• Replace engine oil and filter. 114,000 Miles (183 000 km)
96,000 Miles (154 000 km)
• Replace engine oil and filter. 117,000 Miles (187 000 km)
• Drain and refill automatic transmission fluid. • Replace engine oil and filter.
• Inspect front wheel bearings. Clean and repack, 120,000 Miles (192 000 km)
if required (4x2). • Replace engine oil and filter.
• Change rear axle fluid. • Replace engine a i r cleaner element.
® Change front axle fluid (4x4). • Replace i g n i t i o n cables.
• Inspect brake linings. • Replace spark plugs.
® Replace engine oil and filter. • Change rear axle fluid.
© Change front axle fluid (4x4).
• Replace engine oil and filter. *Off-the-highway operation, trailer towing snow
plowing, prolonged operation with heavy.. loading,
105,000 Miles (168 000 km) especially i n hot weather require the more frequent
• Replace engine oil and filter. transmission service indicated with a * in Sched
ule—B. Perform these services i f the vehicle is oper
108,000 Miles (178 000 km) ated under these conditions.
MAINTENANCE S C H E D U L E S — H E A V Y DUTY V E H I C L E S
INDEX
page page
GENERAL INFORMATION INTRODUCTION . . . . . 12

HEAVY DUTY SCHEDULE—A 12 UNSCHEDULED INSPECTION .. 12
HEAVY DUTY SCHEDULE—B 14
GENERAL INFORMATION Once A Month

• Check tire pressure and look for unusual wear
The following is a list of Maintenance Schedules » Inspect battery and clean and tighten terminals
for Heavy Duty Cycle vehicles (Federal Only - 2500 as required.
8.0L HD and 3500 5.0L & 8.0L Models). • Check fluid levels of coolant reservoir, brake
cle is subjected to. Use the schedule that best • Check all lights and all other electrical items for
to be performed under normal operating conditions At Each Oil Change
for Heavy Duty vehicles. • Inspect exhaust system.
Heavy Duty vehicles operated under the following • Rotate the tires at each oil change interval
• Frequent short trip driving less than 5 miles (8 interval shown on Schedule—B (6,000 Miles).
km) • Check engine coolant level, hoses, and clamps.
• Frequent driving in dusty conditions • I f your mileage is less than 7,500 miles (12 000
• Frequent trailer towing km) yearly, replace the engine oil filter at each oil
• Extensive idling change.
• More than 50% of your driving is at sustained • Lubricate steering linkage.
high speeds during hot weather, above 90°F (32°C) • Replace engine oil filter at every oil change (8.0L
Where time and mileage are listed, follow the only).
HEAVY DUTY SCHEDULE—A
emission control system maintenance
The schedule emission maintenance listed in bold 6,000 miles (10 000 km) or at 6 months
type on the following schedules, must be done at the • Change engine oil.
mileage specified to assure the continued proper • Replace engine oil filter (8.0L only).
functioning of the emission control system. These,
and all other maintenance services included in this 12,000 Miles (19 000 km) or at 12 months
manual, should be done to provide the best vehicle • Change engine oil.
performance and reliability. More frequent mainte • Replace engine oil filter.
nance may be needed for vehicles in severe operating
conditions such as dusty areas and very short trip 18,000 Miles (29 000 km) or at 18 months
driving. • Change engine oil.
• Replace engine oil filter (8.0L only).
UNSCHEDULED INSPECTION • Inspect brake linings
At Each Stop For Fuel 24,000 Miles (38 000 km) or at 24 months
• Check engine oil level and add as required. • Change engine oil.
• Check windshield washer solvent and add as • Replace engine oil filter.
required. • Replace engine air cleaner element and air
pump filter.
• Clean and relubricate crankcase inlet air filter 66,000 Miles (106 000 km) or at 66 months
(5.9L). • Change engine oil.
• Drain and refill automatic transmission fluid. • Replace engine oil filter (8.0L only).
• inspect front wheel bearings. Clean and repack, 72,000 Miles (115 000 km) or at 72 months
If required (4x2). • Change engine oil.
30,000 Miles (48 000 km) or at 80 months • Replace engine air cleaner element and air
• Change engine oil. pump filter.
• Replace engine oil filter (8.0L only). • Drain and refill automatic transmission fluid.
• Replace spark plugs. Replace filter and adjust bands.
36,000 Miles (58 000 km) or at 36 months • Inspect front wheel bearings. Clean and repack,
• Change engine oil. if required (4x2).
® Replace engine oil filter. • Inspect brake linings.
• Flush and replace engine coolant at 36 months, • Change engine oil.
regardless of mileage. © Replace engine oil filter (8.0L only).
42,000 Miles (67 000 km) or at 42 months 30,000 miles (48 000 km) or 24 months since last
• Change engine oil. change.
48,000 Miles (77 000 km) or at 48 months) • Replace oxygen sensor (5.9L only).*
• Replace engine oil filter. 84,000 Miles (134 000 km) or at 84 months
• Replace engine air cleaner element and air • Change engine oil.
pump filter. • Replace engine oil filter.
• Drain and refill automatic transmission fluid. • Flush and replace engine coolant i f i t has been
Replace filter and adjust bands. 30,000 miles (48 000 km) or 24 months since last
• Inspect front wheel bearings. Clean and repack, change.
if required (4x2).
• Flush and replace engine coolant i f not done at 90,000 Miles (144 000 km) or at 90 months
36 months. • Change engine oil.
54,000 Miles (86 000 km) or at 54 months • Replace spark plugs.
• Change engine oil. • Inspect brake linings.
60,000 Miles (96 000 km) or at 60 months • Replace engine oil filter.
• Change engine oil. • Replace engine air cleaner element and air
• Replace engine oil filter. pump filter.
• Replace ignition cables. • Drain and refill automatic transmission fluid.
• Replace P C V valve (5.9L).* Replace filter and adjust bands.
• Replace distributor cap and rotor (5.9L • Inspect front wheel bearings. Clean and repack,
only). if required (4x2). •
• Replace spark plugs.
• Clean EGR air passages (5.9L i f equipped).* 102,000 Miles (163 000 km) or at 102 months
• Replace EGR valve (5.9L i f equipped).* • Change engine oil.
• Replace battery. • Replace engine oil filter (8.0L only).
30,000 miles (48 000 km) or 24 months since last 108,000 Miles (173 000 km) or at 108 months
change. • Change engine oil.
• Inspect brake linings. • Change front axle fluid (4x4).
• Flush and replace engine coolant If it has been ® Inspect front wheel bearings. Clean and repack,
30,000 miles (48 000 km) or 24 months since last if required (4x2).
change. • Inspect brake linings.
^Requires Service Reminder Indicator Light. I f so
equipped, these parts are to be replaced at the indi 27,000 Miles (43 000 km)
cated mileage or when the service reminder indicator • Change engine oil.
light remains on continuously with the key in the • Replace engine oil filter (8.0L only).
"ON" position, whichever occurs first.
30,000 Miles (48 000 km)
HEAVY DUTY SCHEDULE—B • Change engine oil.
3,000 Miles (5 000 km) • Inspect P C V valve, replace as necessary
• Change engine oil. (5.9L).
• Replace engine oil filter (8.0L only). • Replace spark plugs.
6,000 Miles (10 000 km) 33,000 Miles (53 000 km)
• Replace engine oil filter. • Replace engine oil filter (8.0L only).
9,000 Miles (14 000 km) 36,000 Miles (58 000 km)
© Change engine oil. • Change engine oil.
• Replace engine oil filter (8.0L only). • Replace engine oil filter.
• Inspect engine air cleaner element and air
12,000 Miles (19 000 km) pump filter, replace as necessary.
• Change engine oil. • Drain and refill automatic transmission fluid.
• Replace engine oil filter. Replace filter and adjust bands.**
• Inspect engine air cleaner element and air • Drain and refill transfer case.
pump filter, replace as necessary. • Change rear axle fluid.
• Clean and relubricate crankcase inlet air filter • Change front axle fluid (4x4).
(5.9L). • Inspect brake linings.
Replace filter and adjust bands.** 39,000 Miles (62 000 km)
• Change rear axle fluid. • Change engine oil.
o Change front axle fluid (4x4). • Replace engine oil filter (8.0L only).
42,000 Miles (67 000 km)
45,000 Miles (72 000 km)
® Change engine oil. © Replace engine oil filter (8.0L only).
48,000 Miles (77 000 km)
• Replace engine oil filter (8.0L only). • Replace engine air cleaner element and air
pump filter.
24,000 Miles (38 000 km) • Drain and refill automatic transmission fluid.
• Change engine oil Replace filter and adjust bands.
• Replace engine oil filter. • Change rear axle fluid.
• Replace engine air cleaner element and air • Change front axle fluid (4x4).
pump filter. • Inspect front wheel bearings. Clean and repack,
® Drain and refill automatic transmission fluid. if required (4x2).
Replace filter and adjust bands. • Inspect brake linings.
• Change rear axle fluid. • Flush and replace engine coolant.
LUBRICATION AND MAINTENANCE 0 -15
51,000 Miles (82 000 km) 75,000 Miles (120 000 km)
• Replace engine oil filter (8.0L only). • Replace engine oil filter (8.0L only).
54,000 Miles (86 000 km) 78,000 Miles (125 000 km)
© Flush and replace engine coolant.
57,000 Miles (91 000 km)
• Change engine oil. 81,000 Miles (130 000 km)
© Replace engine oil filter (8.0L only). © Change engine oil.
60,000 Miles (96 000 km)
• Replace engine oil filter. • Replace oxygen sensor (5.9L only).*
• Inspect engine air cleaner element and air
pump filter, replace as necessary. 84,000 Miles (134 000 km)
• Replace PCV valve (5.9L).* • Change engine oil.
• Replace distributor cap and rotor (5.9L). • Replace engine oil filter.
• Replace ignition cables. © Inspect engine air cleaner element and air
© Replace spark plugs. pump filter, replace as necessary.
• Clean EGR passages (5.9L i f equipped).* • Drain and refill automatic transmission fluid.
• Replace EGR valve (5.9L i f equipped).* Replace filter and adjust bands.**
• Replace battery. • Change rear axle fluid.
• Drain and refill automatic transmission fluid. • Change front axle fluid (4x4).
Replace filter and adjust bands.** • Inspect brake linings.
• Inspect brake linings. • Change engine oil.
63,000 Miles (101 000 km)
• Replace engine oil filter (8.0L only). ® Change engine oil.
o Replace engine oil filter.
66,000 Miles (106 000 km) • Inspect P C V valve, replace as necessary
• Change engine oil. (5.9L).
• Replace engine oil filter. © Replace spark plugs.
69,000 Miles (110 000 km) 93,000 Miles (149 000 km)
© Change engine oil. © Change engine oil.
© Replace engine oil filter (8.0L only). • Replace engine oil filter (8.0L only).
72, 000 Miles (115 000 km) 96,000 Miles (154 000 km)
© Change engine oil. • Change engine oil.
• Replace engine oil filter. ® Replace engine oil filter.
• Replace engine air cleaner element and air • Replace engine air cleaner element and air
pump filter. pump filter.
• Clean and relubricate crankcase inlet air filter • Drain and refill automatic transmission fluid.
(5.9L). Replace filter and adjust bands.
• Drain and refill automatic transmission fluid. © Change rear axle fluid.
Replace filter and adjust bands. © Change front axle fluid (4x4).
• Drain and refill transfer case fluid. © Inspect front wheel bearings. Clean and repack,
© Change rear axle fluid. if required (4x2).
• Change front axle fluid (4x4). • Inspect brake linings.
if required (4x2).
9 Change engine oil. • Change rear axle fluid.
• Replace engine oil filter (8.0L only). • Change front axle fluid (4x4).
102,000 Miles (163 000 km) • Flush and replace engine coolant.
• Change engine oil. "^Requires Service Reminder Indicator Light. I f so
• Replace engine oil filter. equipped, these parts are to be replaced at the indi
cated mileage or when the service reminder indicator
105,000 Miles (168 000 km) light remains on continuously with the key in the ON
• Change engine oil. position, whichever occurs first.
• Replace engine oil filter (8.0L only). **Off-the-highway operation, trailer towing, snow
plowing, prolonged operation with heavy loading,
108,000 Miles (173 000 km) especially in hot weather require the more frequent
• Change engine oil. transmission service indicated with a ** in Sched
• Replace engine oil filter. ule—B. Perform these services i f the vehicle is oper
• Inspect engine air cleaner element and air ated under these conditions.
pump filter, replace as necessary. Inspection and service should also be performed
• Drain and refill automatic transmission fluid. anytime a malfunction is observed or suspected.
Replace filter and adjust bands,**
BR LUBRICATION AND MAINTENANCE 0 -17
M A I N T E N A N C E SCHEDULES—DIESEL ENGINE V E H I C L E S
INDEI
page page
GENERAL INFORMATION SCHEDULE—B . 18

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . 17 UNSCHEDULED INSPECTION . . . . . . . . . . 17
SCHEDULE—A 17
G E N E R A L INFORMATION At Each Oil Change

• Inspect exhaust system.
INTRODUCTION • Inspect brake hoses.
The following is a list of Maintenance Schedules • Rotate the tires at each oil change interval
for Diesel Engine equipped vehicles. shown, 6,000 miles (9 600 km) on Schedule —A or
There are two maintenance schedules that show every other interval shown on Schedule—B.
proper service based on the conditions that the vehi • Check engine coolant level, hoses, and clamps.
cle Is subjected to. Use the schedule that best • Lubricate steering linkage.
describes these conditions.
Schedule—A, lists all the scheduled maintenance SCHEDULE—A
to be performed under normal operating conditions
for Diesel Engine equipped vehicles. 6,000 Miles (10 000 km) or at 6 months
Schedule—B, lists maintenance recommended for • Change engine oil and filter.
Diesel Engine equipped vehicles operated under the
following conditions:
• Frequent short trip driving less than 5 miles (8 • Change engine oil and filter.
km) • Inspect water pump weep hole for blockage.
• Frequent driving in dusty conditions • Replace fuel filter.
• Frequent trailer towing
• Extensive Idling
• More than 50% of your driving is at sustained • Change engine oil and filter.
high speeds during hot weather, above 90°F (32°C) • inspect drive belts, replace as necessary.
Where time and .mileage are listed, follow the • Inspect brake linings.
UNSCHEDULED INSPECTION • Change engine oil and filter.
• Adjust valve lash clearance.
At Each Stop For Fuel • Inspect fan hub.
• Check engine oil level, add as required. • Inspect damper.
• Check windshield washer solvent and add i f • Inspect water pump weep hole for blockage.
required. • Replace fuel filter.
Once A Month Replace filter and adjust bands.
• Check tire pressure and look for unusual wear • Inspect front wheel bearings. Clean and repack,
or damage. if required (4x2).
• Inspect battery and clean and tighten terminals
as required. 30,000 Miles (48 000 km) or at 30 months
• Check fluid levels of coolant reservoir, brake • Change engine oil and filter.
master cylinder, power steering, and transmission.
Add fluid as required. 36,000 Miles (58 000 km) or at 36 months
• Check all lights and all other electrical items for ® Change engine oil and filter.
correct operation. • Inspect drive belts, replace as necessary.
• Drain water from fuel filter. • Inspect water pump weep hole for blockage.
• Check Filter Minder®. Replace filter if nec • Replace fuel filter.
essary. • Drain and refill transfer case fluid.
• Flush and replace engine coolant at 86 months, • Change engine oil and filter.
regardless of mileage. • Inspect water pump weep hole for blockage.
• Replace fuel filter.
42,000 Miles (67 000 km) or at 42 months ® Flush and replace engine coolant i f i t has been
• Change engine oil and filter. 30,000 miles (48 000 km) or 24 months since last
change.
• Change engine oil and filter. 90,000 Miles (144 000 km)
• Drain and refill automatic transmission fluid. • Change engine oil and filter.
Replace filter and adjust bands. • Inspect drive belts, replace i f necessary.
• Adjust valve lash clearance. • Inspect brake linings.
• Inspect fan hub.
• Inspect damper. 96,000 Miles (154 000 km) or at 96 months
• Inspect front wheel bearings. Clean and repack, • Change engine oil and filter.
if required (4x2). • Drain and refill automatic transmission fluid.
• Inspect water pump weep hole for blockage. Replace filter and adjust bands.
• Replace fuel filter. • Adjust valve lash clearance.
• Flush and replace engine coolant i f not done at • Inspect fan hub.
36 months. • Inspect damper.
54,000 Miles (86 000 km) or at 54 months if required (4x2).
• Change engine oil and filter. • Inspect water pump weep hole for blockage.
• Inspect drive belts, replace as necessary. • Replace fuel filter.
60,000 Miles (96 000 km) or at 60 months • Change engine oil and filter.
• Change engine oil and filter.
• Inspect water pump weep hole for blockage. 108,000 Miles (173 000 km) or at 108 months
• Replace fuel filter. • Change engine oil and filter.
• Flush and replace engine coolant i f it has been © Inspect drive belts, replace as necessary.
30,000 miles (48 000 km) or 24 months since last ® Inspect water pump weep hole for blockage.
change. • Replace fuel filter.
© Drain and refill transfer case fluid.
66,000 Miles (106 000 km) or at 66 months • Inspect brake linings.
© Change engine oil. and filter. • Flush and replace engine coolant i f i t has been
30,000 miles (48 000 km) or 24 months since last
72,000 Miles (115 000 km) or at 72 months change.
• Inspect drive belts, replace as required. SCHEDULE—B
• Drain and refill transfer case fluid. • Change engine oil and filter.
• Inspect fan hub. 6,000 Miles (10 000 km)
• Inspect damper. • Change engine oil and filter.
• Inspect water pump weep hole for blockage.
• Replace fuel filter. 9,000 Miles (14 000 km)
if required (4x2).
78,000 Miles (125 000 km) or at 78 months • Inspect water pump weep hole for blockage.
• Change engine oil and filter. • Replace fuel filter.
• Flush and replace engine coolant i f i t has been • Drain and refill automatic transmission fluid.
30,000 miles (48 000 km) or 24 months since last Replace filter and adjust bands.
change. • Change rear axle fluid.
• Inspect brake linings. • Change engine oil and filter.
15,000 Miles (24 000 km) • Inspect fan hub.
• Change engine oil and filter. • Inspect damper.
18,000 Miles (29 000 km) • Replace fuel filter.
• Change engine oil and filter. • Drain and refill automatic transmission fluid.
• Inspect drive belts, replace as necessary. Replace filter and adjust bands.
® Change rear axle fluid.
21,000 Miles (34 000 km) • Change front axle fluid (4x4).
© Change engine oil and filter. . • Inspect front wheel bearings. Clean and repack
if required (4x2).
24,000 Miles (38 000 km)
• Change engine oil and filter. • Flush and replace engine coolant.
• Inspect fan hub. 51,000 Miles (82 000 km)
• Inspect damper. • Change engine oil and filter.
Replace filter and adjust bands. • Inspect drive belts, replace as necessary.
© Change front axle fluid (4x4). 57,000 Miles (91 000 km)
if required (4x2).
27,000 Miles (43 000 km) • Inspect water pump weep hole for blockage.
• Change engine oil and filter. 9 Replace fuel filter.
® Drain and refill automatic transmission fluid.
• Change engine oil and filter. • Change rear axle fluid.
63,000 Miles (101 000 km)
36,000 Miles (58 000 km) • Change engine oil and filter.
• Inspect drive belts, replace as necessary. 66,000 Miles (106 000 km)
• Inspect water pump weep hole for blockage. • Change engine oil and filter.
• Replace fuel filter.
• Drain and refill automatic transmission fluid. 69,000 Miles (110 000 km)
Replace filter and adjust bands. • Change engine oil and filter.
• Change rear axle fluid. 72,000 Miles (115 000 km)
• Change front axle fluid (4x4). • Change engine oil and filter.
• Inspect brake linings. • Inspect drive belts, replace as necessary.
® Adjust valve lash clearance.
39,000 Miles (62,000 km) • Inspect fan hub.
• Change engine oil and filter. • Inspect damper.
42,000 Miles (67 000 km) © Replace fuel filter.
• Change engine oil and filter. ® Drain and refill automatic transmission fluid.
• Change engine oil and filter. © Change rear axle fluid.
I - 20 LUBRICATION AND MAINTENANCE mm
© Change front axle fluid (4x4). © Inspect fan hub.
• Inspect front wheel bearings. Clean and repack 9 Inspect damper.
if required (4x2). • Inspect water pump weep hole for blockage.
• Inspect brake linings. • Replace fuel filter.
© Drain and refill automatic transmission fluid.
• Change engine oil and filter. • Change rear axle fluid.
78,000 Miles (125 000 km) • Inspect front wheel bearings. Clean and repack
• Change engine oil and filter. if required (4x2).
• Flush and replace engine coolant. • Inspect brake linings.
81,000 Miles (130 000 km) 99,000 Miles (158 000 km)
• Change engine oil and filter. • Change engine oil and filter.
84,000 Miles (134 000 km) 102,000 Miles (163 000 km)
• Change engine oil and filter. • Change engine oil and filter.
© Change rear axle fluid. 108,000 Miles (173 000 km)
• Change front axle fluid (4x4). • Change engine oil and filter.
• Inspect brake linings. • Clean engine air filter canister.
• Inspect drive belts, replace as necessary.
87,000 Miles (139 000 km) • Inspect water pump weep hole for blockage.
• Change engine oil and filter. • Replace fuel filter.
• Change engine oil and filter. • Drain and refill transfer case fluid.
• Inspect drive belts, replace as necessary. • Change rear axle fluid.
• Change engine oil and filter. • Flush and replace engine coolant.
96,000 Miles (154 000 km)
® Adjust valve lash clearance.
m LUBRICATION AND MAINTENANCE 0 - 21
J U M P STARTING, TOWING AND HOISTING
INDEX
page page
SERVICE PROCEDURES J U M P STARTING PROCEDURE ... ...... 21

FOUR-WHEEL-DRIVE VEHICLE TOWING . . . . . 23 TOWING RECOMMENDATIONS . . . . . . . . . 22
HOISTING RECOMMENDATIONS 23 TWO-WHEEL-DRIVE VEHICLE TOWING ...... 23
SERVICE PROCEDURES park or neutral, set park brake and operate engine at
1200 rpm.
JUMP STARTING PROCEDURE (3) On disabled vehicle, place gear selector in park
or neutral and set park brake. Turn off all accesso
WARNING: REVIEW ALL SAFETY PRECAUTIONS ries.
AND WARNINGS IN GROUP 8A, BATTERY/START (4) Connect jumper cables to booster battery. RED
ING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT clamp to positive terminal (+). BLACK clamp to neg
JUMP START A FROZEN BATTERY, PERSONAL ative terminal (-). DO NOT allow clamps at opposite
INJURY CAN RESULT DO NOT JUMP START WHEN end of cables to touch, electrical arc will result.
MAINTENANCE FREE BATTERY INDICATOR DOT IS Review all warnings in this procedure.
YELLOW OR BRIGHT COLOR. DO NOT JUMP (5) On disabled vehicle, connect RED jumper cable
START A VEHICLE WHEN THE BATTERY FLUID IS clamp to positive (+) terminal. Connect BLACK
BELOW THE TOP OF LEAD PLATES. DO NOT jumper cable clamp to engine ground as close to the
ALLOW JUMPER CABLE CLAMPS TO TOUCH ground cable attaching point as possible (Fig. 1) and
EACH OTHER WHEN CONNECTED TO A BOOSTER (Fig. 2).
SOURCE. DO NOT USE OPEN FLAME NEAR BAT
TERY. REMOVE METALLIC JEWELRY WORN ON CAUTION: Do not crank starter motor on disabled
HANDS OR WRISTS TO AVOID INJURY BY ACCI vehicle for more than 15 seconds, starter will over
DENTAL ARCING OF BATTERY CURRENT. WHEN heat and could fail.
USING A HIGH OUTPUT BOOSTING DEVICE, DO
NOT ALLOW BATTERY VOLTAGE TO EXCEED 16 (6) Allow battery in disabled vehicle to charge to
VOLTS. REFER TO INSTRUCTIONS PROVIDED at least 12.4 volts (75% charge) before attempting to
WITH DEVICE BEING USED. start engine. I f engine does not start within 15 sec
onds, stop cranking engine and allow starter to cool
(15 min.), before cranking again.
CAUTION: When using another vehicle as a
NEGATIVE O R - —
booster, do not allow vehicles to touch. Electrical G R O U N D CABLE ™ POSITIVE
systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:

(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
• Battery cable clamp condition, clean i f necessary.
• Frozen battery.
• Yellow or bright color test indicator, i f equipped.
• Low battery fluid level.
© Generator drive belt condition and tension.
• Fuel fumes or leakage, correct i f necessary.
CAUTION: If the cause of starting problem on dis

abled vehicle is severe, damage to booster vehicle
Fig. 1 Jumper Cable Clamp Connections—Gas
charging system can result.
Engine
(2) When using another vehicle as a booster
source, turn off all accessories, place gear selector in
0 - 22 LUBRICATION AND MAINTENANCE BR
S E R V I C E P R O C E D U R E S (Continued)
W H E E L LIFT
Fig. 2 Jumper Cable Clamp Connections—Diesel

Engine
DiSCONIECT CA1LE CHIPS AS FOLLOWS: FLAT BED
• Disconnect BLACK cable clamp from engine ™ " J9500-6
ground on disabled vehicle.

• When using a Booster vehicle, disconnect Fig. 3 Tow Vehicles With Approved Equipment
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive • Do not tow a vehicle in a manner that could
terminal. jeopardize the safety of the operator, pedestrians or
• Disconnect RED cable clamp from battery posi other motorists.
tive terminal on disabled vehicle. • Do not attach tow chains, T-hooks, J-hooks, or a
tow sling to a bumper, steering linkage, drive shafts
TOWING RECOMMENDATIONS or a non-reinforced frame hole.
A vehicle equipped with SAE approved sling-type • Do not tow a heavily loaded vehicle. Damage to
towing equipment can be used to tow all vehicles. the cab, cargo box or frame may result. Use a flatbed
When towing a 4WD vehicle using a wheel-lift towing device to transport a loaded vehicle.
device, use a tow dolly under the opposite end of the
vehicle. A vehicle with flat-bed device can also be GROUND CLEARANCE
used to transport a disabled vehicle (Fig. 3).
CAUTION: If vehicle is towed with wheels
A wooden crossbeam may be required for proper
removed, install lug nuts to retain brake drums or
connection when using the sling-type, front-end tow
rotors.
ing method.
A towed vehicle should be raised until lifted wheels
SAFETY PRECAUTIONS
are a minimum 100 mm (4 in) from the ground. Be
CAUTION: The following safety precautions must sure there is adequate ground clearance at the oppo
be observed when towing a vehicle; site end of the vehicle, especially when towing over
rough terrain or steep rises in the road. I f necessary,
• Secure loose and protruding parts. remove the wheels from the lifted end of the vehicle
• Always use a safety chain system that is inde and lower the vehicle closer to the ground, to
pendent of the lifting and towing equipment. increase the ground clearance at the opposite end of
• Do not allow towing equipment to contact the the vehicle. Install lug nuts on wheel attaching studs
disabled vehicle's fuel tank. to retain brake drums or rotors.
, • Do not allow anyone under the disabled vehicle
while It is lifted by the towing device. RAMP ANGLE
• Do not allow passengers to ride In a vehicle . I f a vehicle with flat-bed towing equipment is used,
being towed. the. approach ramp angle should not exceed 15
• Always observe state and local laws regarding degrees.
towing regulations.
TOWING WHEN KEYS ARE MOT AVAILABLE • An axle tube.
When the vehicle is locked and keys are not avail • A body side sill.
able, use a flat bed hauler. A Wheel-lift or Sling-type • A steering linkage component.
device can be used on 4WD vehicles provided a l l the • A drive shaft.
wheels are lifted off the ground using tow dol • The engine or transmission oil pan.
lies. • The fuel tank.
© A front suspension arm.
TWO-WHEEL-DRIVE VEHICLE TOWING
Chrysler Corporation recommends that a vehicle be
towed with the rear end lifted, whenever possible. NOTE: Use the correct frame rail lifting locations
only (Fig. 4 ) .
TOWING-RBAR END LIFTED
CAUTION: Do not use steering column lock to HOIST

secure steering wheel during towing operation. A vehicle can be lifted with:
• A single-post, frame-contact hoist.
• Unlock steering column and secure steering • A twin-post, chassis hoist.
wheel in straight ahead position with a clamp device • A ramp-type, drive-on hoist.
designed for towing.
• Verify that steering components are in good con NOTE: When a frame-contact type hoist is used,
dition. verify that the lifting pads are positioned properly
(Fig. 4),
TOWING-FRONT END LIFTED
If a two-wheel-drive vehicle cannot be towed with
the rear wheels lifted, it can be towed with the front
wheels lifted with the transmission in the neutral
position.
FOUR-WHEEL-DRIVE VEHICLE TOWING

Chrysler Corporation recommends that a vehicle be
transported on a flat-bed device. A Wheel-lift or
Sling-type device can be used provided all the wheels
are lifted off the ground using tow dollies.
HOISTING RECOMMENDATIONS
Refer to the Owner's Manual for emergency vehicle
lifting procedures.
WARNING: THE HOISTING AND JACK LIFTING

POINTS PROVIDED ARE FOR A COMPLETE VEHI
CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO
NENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
SUPPORT OR SECURE VEHICLE TO HOISTING
DEVICE WHEN THESE CONDITIONS EXIST.
FLOOR JACK
J9500-5
When properly positioned, a floor jack can be used
to lift a vehicle (Fig. 4). Support the vehicle in the
raised position with jack stands at the front and rear Fig. 4 Vehicle Lifting Locations
ends of the frame rails.
CAUTION: Do not lift vehicle with a floor jack posi

tioned under:
SUSPENSION 2 - 1
SUSPENSION
CONTENTS
page page
FRONT SUSPENSION (IFS) 8 REAR SUSPENSION 21

FRONT SUSPENSION LINK/COIL 15 WHEEL ALIGNMENT 1
WHEEL ALIGNMENT
INDEX
page page
GENERAL INFORMATION ALIGNMENT LINK/COIL SUSPENSION 4

FRAME COATINGS INFORMATION 1 CAB-CHASSIS CASTER CORRECTION
DESCRIPTION AND OPERATION MEASURMENT 5
WHEEL ALIGNMENT 1 PRE-ALIGNMENT INSPECTION 2
SERVICE PROCEDURES SPECIFICATIONS
ALIGNMENT IFS SUSPENSION 4 ALIGNMENT SPECIFICATION 7
GENERAL INFORMATION positioning is accomplished through suspension and

steering linkage adjustments. An alignment is con
FRAME COATINGS INFORMATION sidered essential for efficient steering, good direc
tional stability and to maximize tire wear. The most
CAUTION: Depending on the vehicle build location, important measurements of front end alignment are
there are two different coatings applied to BR frames: caster, camber and toe position (Fig. 1) and (Fig. 2).
11th NOTE: Routine inspection of the front suspension

VEHICLE and steering components is a good preventative
POSITION FRAME
BUILD maintenance practice. Inspection also helps to
VIN COATING
LOCATION ensure safe operation of the vehicle.
CHARACTER
St. Louis North J E-Coat • CASTER is the forward or rearward tilt of the
Dodge City S Wax Coat steering knuckle from vertical. Tilting the top of the
knuckle rearward provides positive caster. Tilting the
Saltillo Mexico G Wax Coat top of the knuckle forward provides negative caster.
Lago Alberto M Wax Coat Caster is a directional stability angle which enables
Mexico the front wheels to return to a straight ahead posi
tion after turns.
Replacement fasteners and torque values for • CAMBER is the inward or outward tilt of the
frame attached components may vary depending on wheel relative to the center of the vehicle. Tilting the
frame coatings. Ensure the replacement fastener is top of the wheel inward provides negative camber.
designed for the specific frame coating. Refer to the Tilting the top of the wheel outward provides positive
Torque Specifications Chart at the end of each camber. Incorrect camber will cause wear on the
group to determine the correct torque value. inside or outside edge of the tire.
• WHEEL TOE POSITION is the difference
between the leading inside edges and trailing inside
DESCRIPTION AND OPERATION edges of the front tires. Incorrect wheel toe position
is the most common cause of unstable steering and
WHEEL ALIGNMENT uneven tire wear. The wheel toe position is the final
front wheel alignment adjustment.
Front wheel alignment involves the correct posi
tioning of the wheels in relation to the vehicle. The
2 -2 SUSPENSION BR
D E S C R I P T I O N A N D O P E R A T I O N {Continued)
• STEERING AXIS INCLINATION ANGLE is POSITIVE NEGATIVE POSITIVE NEGATIVE
measured in degrees. I t is the angle that the steering
knuckles are tilted (Fig. 1). The inclination angle has
a fixed relationship with the camber angle. I t will not
change except when a spindle or bail stud is dam
aged or bent. The angle is not adjustable and the
damaged component(s) must be replaced to correct
mis-alignment. STEERING AXIS INCLINATION
CAUTION; Do not attempt to modify any suspension

or steering components by heating and bending,
SERVICE PROCEDURES
J9402-56
PRE-AUGNMENT INSPECTION
Before starting wheel alignment, the following Fig. 1 Aiignment Angles IFS
inspection and necessary corrections must be com
pleted. Refer to Suspension and Steering System (4) Inspect ball studs, linkage pivot points and
Diagnosis Chart for additional information. steering gear for looseness, roughness, binding or a
(1) Tires with the same recommended air pressure, sticking condition. Refer to Group 19, Steering for
size, and tread wear. Refer to Group 22, Wheels and additional information.
Tires for diagnosis information. (5) Inspect suspension components for wear and
(2) Inspect front wheel bearings for wear or adjust noise. Check components for correct torque.
ment.
(3) Inspect front wheels for excessive radial, lat
eral runout and unbalance. Refer to Group 22,
Wheels and Tires for diagnosis information.
CAMBER
WHEEL
TRUE CENTERLINE
VERTICAL NEGATIVE
CAMBER
ANGLE
PIVOT
CENTERLINE
SCRUB
- RADIUS FRONT OF VEHICLE
POSITIVE CAMBER (NOT SHOWN) — B —
TOP OF WHEEL OUTBOARD NEGATIVE TOE (TOE OUT) B > A
POSITIVE TOE (TOE IN) B < A
CASTER
POSITIVE CASTER- *i THRUST ANGLE
KING PIN
h
OF VEHICLE f
V VERTICAL
RE
ANGLE OF REAR AXLE
RELATIVE TO VEHICLE CENTERLINE
( + ) AXLE POINTS LEFT
IE
(-) AXLE POINTS RIGHT
J9402-57
Fig. 2 Alignment Angles Link/Coil

BR • • . . . — . . SUSPENSION 2 - 3
SERVICE PROCEDURES (Continued)
SUSPENSION AND STEERING SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
FRONT END NOISE 1. Loose or worn front wheel 1. Adjust or replace wheel bearings.
bearings.
2 . Loose or worn suspension 2 . Replace worn bushings or suspension components.
bushings or components.
EXCESSIVE PLAY IN 1. Loose or worn front wheel 1. Adjust or replace wheel bearings.
STEERING bearings.
2 . Loose or worn steering 2 . Replace loose or worn steering components.
components.
3. Loose or worn steering gear. 3 . Adjust or replace steering gear.
FRONT WHEELS SHIMMY 1. Loose or worn front wheel 1. Adjust or replace wheel bearings.
bearings.
3. Tires worn or out of balance. 3. Replace or balance tires as needed.
4 . Alignment. 4 . Align front end.
VEHICLE INSTABILITY 1. Loose or worn front wheel 1. Adjust or replace wheel bearings.
bearings.
3. Loose or worn suspension 3 . Replace worn bushings or suspension components.
4 . Weak or broken spring. 4 . Replace weak or broken spring.
5. Tire pressure. 5 . Correct tire pressure.
DIFFICULT STEERING 1. Tire pressure. 1. Correct tire pressure.

3 . Steering gear or pump. 3. Adjust or replace steering gear. Test and repair pump as
needed.
VEHICLE PULLS TO 1. Tire pressure. 1. Correct tire pressure.

ONE SIDE 2 . Alignment. 2 . Align front end.
4 . Weak or broken spring. 4 . Replace weak or broken spring.
5. Brake pull. 5. Repair brakes.
J9502-5
2 - 4 SUSPENSION BR
ALIGNMENT IFS SUSPENSION NOTE: Each front wheel should be adjusted for
Before each alignment reading the vehicle should one-half of the total toe position specification. This
be jounced (rear first, then front). Grasp each will ensure the steering wheel will be centered
bumper at the center and jounce the vehicle up and when the wheels are positioned straight-ahead.
down several times. Always release the bumper in
the down position. Set the front end alignment to (3) Adjust the wheel toe position by turning the tie
specifications while the vehicle is i n its NOR rod adjustment sleeves as necessary.
MALLY LOADED CONDITION.
Camber and caster angle' adjustments involve ALIGNMENT LINK/COIL SUSPENSION
changing the position of the upper suspension arm Before each alignment reading the vehicle should
pivot bar (Fig. 3). Refer, to the Alignment Specifica be jounced (rear first, then front). Grasp each
tion Chart for the correct setting. bumper at the center and jounce the vehicle up and
down several times. Always release the bumper in
the down position. Set the front end alignment to
specifications while the vehicle is in its NOR
MALLY LOADED CONDITION,
CAMBER: The wheel camber angle is preset and
is not adjustable.
CASTER: Check the caster of the front axle for
correct angle. Be sure the axle is not bent or twisted.
Road test the vehicle and make left and right turn.
Observe the steering wheel return-to-center position.
Low caster will cause poor steering wheel returnabil-
ity.
Caster can be adjusted by rotating the cams on the
lower suspension arm (Fig. 4). Refer to the Align
ment Specification for the correct setting.
Fig. 3 Caster Camber Adjustment Location

CASTER: Move only the rear position of the pivot
bar i n or out. This will change the caster angle sig
nificantly and camber angle only slightly. To retain
the camber while adjusting caster, move the rear
pivot bar in or out. Move the forward pivot very
slightly in the opposite direction.
NOTE; For example, to increase a positive caster

angle, move the rear position of the pivot bar
inward (toward the engine). Howe the front of pivot
bar outward (away from the engine) slightly until
the original camber angle is obtained.
CAMBER: Move only the forward position of the

pivot bar in or out. This will change the camber
angle significantly and caster angle only slightly. The
camber angle should be adjusted as close as possible
to the preferred service specification. After
adjustment is made tighten pivot bar nuts to specifi J9302-59
cations.
T O E POSITION: The wheel toe position adjust Fig. 4 Cam Adjuster
ment should be the final adjustment. T O E POSITION: The wheel toe position adjust
(1) Start the engine and turn wheels both ways ment should be the final adjustment.
before straightening the wheels. Center and secure (1) Start the engine and turn wheels both ways
the steering wheel and turn off engine. before straightening the wheels. Center and Secure
(2) Loosen the tie rod adjustment sleeve clamp the steering wheel and turn off engine.
bolts/nuts. (2) Loosen the adjustment sleeve clamp bolts.
BR SUSPENSION 2- S
(3) Adjust the right wheel toe position with the their original position and tighten to specifications.
drag link (Fig. 5). Turn the sleeve until the right Make sure the toe setting does not change dur
wheel is at the correct TOE-IN position. Position ing clamp tightening.
clamp bolts to their original position and tighten to (5) Verify the right toe setting.
specifications. Make sure the toe setting does not
change during clamp tightening. CAB-CHASSIS CASTER CORRECTION
MEASURMENT
S T E E R I N G DAMPENER To determine the correct caster alignment angle for
Cab- Chassis vehicles the following procedure must
be performed.
(1) Take a height measurement to the center of the
front gauge hole in the frame. Take another mean-
surement to the center of the rear spring hanger bolt
(Fig. 6). Take these measurements on both sides of
the vehicle.
803f5895
Fig. 5 Drag Link Adjustment

(4) Adjust left wheel toe position with tie rod at
left knuckle. Turn the sleeve until the left wheel is at
the correct TOE-IN position. Position clamp bolts to
4x2
GAUGE
HOLE HANGER
BOLT
4x4
J9502-14
Fig. 6 Cab-Chassis Measurement

2 -6 SUSPENSION BR
(2) Subtract the front measurement from the rear
measurement and use the average between the right 134.7" o r 138.7"
WHEELBASE WHEELBASE
and left side. Use this number with the Caster Cor
rection Chart to obtain the correct caster angle (Fig. H a n g e r Bolt- Coster H a n g e r Bofit- Caster
7). G a u g e Hole Correction G a u g e Hole Correction
pitches! (degrees) (inches) (degrees)
-5.00 -0.23 -5.00 -0.19

-4.75 -0.11 -4.75 -0.09
-4.50 0.01 -4.50 0.01
-4.25 0.14 -4.25 0.11
-4.00 0.26 -4.00 0.21
-3.75 0.38 -3.75 0.31
-3.50 0.50 -3.50 0.41
-3.25 0.62 -3.25 0.51
-3.00 0.75 -3.00 0.61
-2.75 0.87 -2.75 0.71
-2.50 0.99 -2.50 0.81
-2.25 1.11 -2.25 0.91
-2.00 1.24 -2.00 1.01
-1.75 1.36 -1.75 1.11
-1.50 1.48 -1.50 1.21
-1.25 1.60 -1.25 1.31
-1.00 1.73 -1.00 1.41
-0.75 1.85 -0.75 1.51
-0.50 1.97 -0.50 1.61
-0.25 2.09 -0.25 1.71
0.00 2.21 0.00 1.81
J9502-15
Fig. 7 Caster Correction Chart

BR SUSPENSION 2-7
SPECIFICATIONS
ALIGNMENT SPECIFICATION
PREFERRED PREFERRED
©WW WHEEL CASTER CAMBER
4x214x4 BASE
(lbs) (inches)
(degrees) (degrees)
( + / - 1.00) ( + / - 0.50)
4x2 6010 118.7 3.65 0.50

4x2 6400 118.7 3.65 0.50
4x2 6010 134.7 3.80 0.50
4x2 6400 134.7 3.80 0.50
4x2 6400 138.7 3.70 0.50
4x2 6400 154.7 3.85 0.50
4x2 7500 134.7 3.55 0.50
4x2 8800 134.7 3.45 0.50
4x2 8800 154.7 3.65 0.50
4x2 10500 134.7 3.25 0.50
4x2 10500 154.7 3.45 0.50
4x4 6400 118.7 3.35 not set
4x4 6400 134.7 3.45 not set
4x4 6400 138.7 3.40 not set
4x4 6400 154.7 3.55 not set
4x4 7500 134.7 3.00 not set
4x4 8800 134.7 3.10 not set
4x4 8800 154.7 3.25 not set
4x4 10500 134.7 2.90 not set
4x4 10500 154.7 3.00 not set
4x2/4x4 8800 134.7 not set

USE
•4x2/4x4 11000 138.7 CAB-CHASSIS not set
PROCEDURE
•4x2/4x4 11000 162.7 not set
c
Preferred Total Toe-in 0.25 > ( + / - 0.25)
* 4x2 11000# G V W has a solid front axle link coil suspension system.
J9502-16
2 - 8 SUSPENSION BR
FRONT SUSPENSION (IFS)

INDEX
page page
GENERAL INFORMATION UPPER SUSPENSION ARM 11

FRAME COATINGS INFORMATION 8 WHEEL BEARINGS 11
DESCRIPTION AND OPERATION WHEEL STUDS 12
INDEPENDENT FRONT SUSPENSION (IFS) 8 DISASSEMBLY AND ASSEMBLY
DIAGNOSIS AND TESTING LOWER BALL STUD 12
LOWER BALL STUD 9 UPPER BALL STUD 13
SHOCK DIAGNOSIS 9 CLEANING AND INSPECTION
UPPER BALL STUD 9 WHEEL BEARINGS 13
REMOVAL AND INSTALLATION SPECIFICATIONS
COIL SPRINGS 10 IFS SUSPENSION (E-COAT FRAME) 13
LOWER SUSPENSION ARM 10 IFS SUSPENSION (WAX COAT FRAME) 13
SHOCK ABSORBER 9 SPECIAL TOOLS
STABILIZER BAR . 11 IFS FRONT SUSPENSION 14
STEERING KNUCKLE 10
GENERAL INFORMATION Stabilizer bar
SUSPENSION COIL SPRING

FRAME COATINGS INFORMATION ARM
CAUTION: Depending on the vehicle build location, KNUCKLE STABILIZER

BAR
there are two different coatings applied to BR frames:
11th
VEHICLE
POSITION FRAME
BUILD
VIN COATING
LOCATION
CHARACTER
St. Louis North J E-Coat
Dodge City S Wax Coat
SUSPENSION
Saltillo Mexico G Wax Coat ARM
Lago Alberto M Wax Coat J9402-12
Mexico
Fig. 1 independent Front Suspension
Replacement fasteners and torque values for
frame attached components may wary depending on
SHOCK
frame coatings. Ensure the replacement fastener is
designed for the specific frame coating. Refer to the
Torque Specifications Chart at the end of each
group to determine the correct torque value.
DESCRIPTION AND OPERATION
INDEPENDENT FRONT SUSPENSION (IFS)

The IFS suspension is comprised of (Fig. 1) and
(Fig. 2);
• Shock absorbers J9402-13
• Coil springs
• Upper and lower suspension arms Fig. 2 independent Front Suspension
BR SUSPENSION 2-9
D E S C R I P T I O N A N D O P E R A T I O N (Continued)
Shock Absorbers: The shock absorbers dampen SHOCK DIAGNOSIS
jounce and rebound of the vehicle over various road A noise from a shock absorber may be caused by
conditions. Shocks are mounted on the bottom to the movement between mounting bushings and metal
lower suspension arms. The top of the shock mounts brackets or attaching components. This noise can
on frame brackets using grommets. usually be stopped by tightening the attaching nuts.
Coil Springs: The coil springs control ride quality If the noise persists, inspect for damaged and worn
and maintain proper ride height. The springs mount bushings, and attaching components. Repair as nec
between the lower suspension arm and the front essary i f any of these conditions exist.
cross member spring seat. A rubber isolator seats on The shock absorbers are not refillable or adjust
top off the spring to help prevent noise. able. I f a malfunction occurs, the shock absorber
Suspension Arms: The suspension arms have must be replaced. To test a shock absorber, hold i t in
replaceable ball studs which are pressed into the an upright position and force the piston in and out of
arms. Bushings located inboard are not replaceable. the cylinder four or five times. The action throughout
The upper arm has a pivot bar which mounts on a each stroke should be smooth and even.
frame bracket. The bracket has slotted holes this The shock absorber bushings do not require any
allows the arm to be adjusted for caster and camber. type of lubrication. Do not attempt to stop bushing
The suspension arm travel (jounce or rebound) is lim noise by lubricating them. Grease and mineral oil-
ited through the use of urethane bumpers. base lubricants will deteriorate the bushing rubber.
Stabilizer Bar: The stabilizer bar is used to mini
mize vehicle front sway during turns. The spring steel
bar helps to control the vehicle body in relationship to REMOVAL AND INSTALLATION
the suspension. The bar extends across the front under
side of the chassis and mounts on the frame rails. Links SHOCK ABSORBER
connected the bar to the lower suspension arms. Stabi
lizer bar mounts are isolated by rubber bushings. Links WARNING: DO MOT REMOVE SHOCK UNTIL
are isolated with rubber grommet. LOWER SUSPENSION ARM IS SUPPORTED. THE
SHOCK HOLDS THE LOWER SUSPENSION ARM
AND SPRING IN POSITION.
DIAGNOSIS AND TESTING
LOWER BALL STUD REMOVAL

(1) Raise the front of the vehicle. Install safety (1) Raise and support vehicle.
floor stands under both lower suspension arms as far (2) Remove shock upper nut and remove retainer
outboard as possible. The upper suspension arms and grommet.
must not contact the rebound bumpers. (3) Remove lower mounting bolt from suspension
(2) Install a dial indicator and clamp assembly to arm and remove shock (Fig. 3).
the lower suspension arm.
(3) Position indicator plunger against knuckle arm
and zero indicator.
(4) Raise and lower the wheel with a pry bar under
the center of the tire. Measure the axial movement of
the knuckle with respect to the suspension arm.
(5) I f the travel of the suspension arm is 0.030
inch (0.8 mm) or more, replace the ball joint.
UPPER BALL STUD

(1) Position a floor jack under the lower suspension
arm. Raise the wheel and allow the tire to lightly contact
the floor (vehicle weight relieved from the tire).
(2) Mount a dial indicator on the upper suspension
arm. Position the indicator plunger against the upper
ball stud boss of the steering knuckle.
Fig. 3 Shock Absorber
(3) Grasp the top of the tire and apply force in and
out. Look for movement at the ball joint between the
upper suspension arm and steering knuckle.
(4) I f lateral movement is greater than 0.8 mm
(0.030 in.), replace the ball joint.
2 - 10 SUSPENSION BR
R E M O V A L A N D I N S T A L L A T I O N (Continued)
INSTALLATION INSTALLATION
(1) Extend shock fully, install retainer and grom (1) Install rubber isolator on top of spring. Position
met on top of shock absorber. Check grommets and spring into upper spring seat and lower suspension
retainer for wear. arm.
(2) Guide shock up through upper suspension arm (2) Raise suspension arm with jack and position
bracket. Install top grommet, retainer and nut. shock into suspension arm mount. Install shock bolt
Tighten nut to specifications. and tighten to specifications.
(3) Align bottom end of shock into lower suspen (3) Install steering knuckle on lower ball stud.
sion arm and install mounting bolt. Tighten bolt to Install lower ball stud nut and tighten to specifica
specifications. tions. Replace cotter pin and remove jack.
(4) Remove support and lower vehicle. (4) Install stabilizer bar link on lower suspension
arm. Install grommet, retainer and nut and tighten
COIL SPilNOS to specifications.
(5) Install tie rod on steering knuckle and tighten
WARNING: DO NOT REMOVE SHOCK UNTIL nut to specifications.
LOWER SUSPENSION ARM IS SUPPORTED. THE (6) Install brake caliper assembly and rotor, refer
SHOCK HOLDS THE LOWER SUSPENSION ARM to Group 5 Brakes.
AND SPRING IN POSITION. (7) Install tire and wheel assembly.
(8) Remove support and lower vehicle.
REMOVAL
SfEEFtINi KNUCKLE
(1) Raise and support vehicle.
(2) Remove tire and wheel assembly. REMOVAL
(3) Remove brake caliper assembly and rotor refer (1) Raise and support vehicle.
to Group 5 Brakes. (2) Remove wheel and tire assembly. Remove the
(4) Disconnect tie rod from steering knuckle. brake caliper, refer to Group 5 Brakes.
(5) Disconnect stabilizer bar link from lower sus (3) Remove the wheel hub and bearing assembly
pension arm. from the spindle. Refer to Wheel Hub and Bearings
(6) Support lower suspension arm outboard end service removal.
with jack. Place jack under arm in front of shock (4) Remove the cotter pin and nut from the tie-rod
mount. end and disconnect tie rod.
(7) Remove cotter pin and nut from lower ball (5) Remove the cotter pins and nuts from the
stud. Separate ball stud with remover C-4150A. upper and lower ball studs. Separate upper ball stud
(8) Remove lower shock bolt from suspension arm. from knuckle with remover MD-990635. Separate
(9) Lower jack and suspension arm until spring lower ball stud with remover C-4150A and remove
tension is relieved. Remove spring and rubber isola knuckle.
tor (Fig. 4).
INSTALLATION
(1) Position knuckle on ball stud and install ball
stud nuts. Tighten nuts to specifications and install
cotter pins.
(2) Install the brake rotor hub and bearing assem
bly on spindle. Refer to Wheel Hub and Bearings ser
vice installation.
(3) Install the brake caliper, refer to Group 5
Brakes.
(4) Install wheel and tire assembly.
LOWER SUSPENSION ARM
WARNING: DO NOT REMOVE SHOCK UNTIL

LOWER SUSPENSION ARM IS SUPPORTED. THE
S H O C K HOLDS THE LOWER SUSPENSION ARM
Fig. 4 Coil Spring
AND SPRING IN POSITION.
BR SUSPENSION 2 -11
REMOVAL STABILIZER BAR
(2) Follow procedure under Coil Spring Removal. REMOVAL
(3) Remove bolts mounting suspension arm to (1) Raise and support the vehicle.
crossmember and remove arm. (2) Disconnect the link from lower suspension arm
and stabilizer bar (Fig. 6).
INSTALLATION (3) Disconnect the stabilizer bar clamps from the
(1) Position suspension arm on crossmember and frame rails. Remove the stabilizer bar.
install bolts snug.
(2) Follow procedure under Coil Spring Installa
tion.
(4) Tighten suspension arm crossmember bolts to
specifications.
UPPER SUSPENSION ARM
REMOVAL
(2) Remove tire and wheel assembly.
(3) Support lower suspension arm at outboard end
with jack stand.
(4) Remove upper ball stud cotter pin and nut.
(5) Separate ball stud from knuckle with remover
MB-990635.
(6) Remove pivot bar bolts from upper suspension
arm bracket and remove arm from vehicle (Fig. 5).
Fig. 6 STABILIZER BAR

INSTALLATION
(1) Position the stabilizer bar on the frame rail
and install the clamps and bolts. Ensure the bar is
centered with equal spacing on both sides. Tighten
the bolts to specifications.
(2) Install links on stabilizer bar and lower sus
pension arm. Install grommet s, retainers and nuts.
Tighten nuts to specifications.
' (3) Remove the supports and lower the vehicle.
WHEEL BEARINtS
REMOVAL
Fig. 5 Upper Suspension Arm
(1) Raise and support the vehicle.
INSTALLATION (2) Remove the wheel and tire assembly.
(1) Position upper suspension arm on bracket and (3) Remove disc brake caliper from steering
install pivot bar bolts. Tighten to specifications. knuckle. Refer to Group 5 Brakes.
(2) Install ball stud in knuckle. Install nut and (4) Remove the dust cap, cotter pin, and hub nut
tighten to specifications. Install replacement cotter from spindle.
pin.
(3) Remove jack from lower suspension arm. CAUTION: Use care to prevent inner wheel bearing and
(4) Install tire and wheel assembly. seal from contacting spindle threads during removal.
(6) Align front suspension. (5) Carefully slide the hub/rotor from spindle.
(6) Remove the seal and inner wheel bearing from
the hub/rotor.
2 -12 SUSPENSION BR
(7) Remove inner bearing races from hub/rotor (2) Position special tool on lower suspension arm
with a pin punch if bearings are going to be replaced. and press out ball stud (Fig. 7).
INSTALLATION'
(1) Install the new bearing cup(s) with an appro
priate installation tool.
(2) Apply a coating of MOPAR Wheel Bearing
Grease or equivalent lubricant to inner surface area
of hub/rotor. Install inner wheel bearing and seal in
the hub/rotor.
(3) Inspect bearing and seal contact surfaces on
spindle for burrs and/or roughness.
(4) Remove all rough contact surfaces from spin
dle. Apply a coating of lubricant.
CAUTION: Use care to prevent inner wheel bearing

and seal from contacting spindle threads during
installation. SPECIAL TOOL
C-4212F
(5) Carefully slide the hub/rotor onto spindle. Install
outer wheel bearing, washer and retaining nut.
(6) Tighten the nut'to 41-54 N-m (30-40 ft. lbs.)
torque to preload bearing while rotating the hub/rotor.
Stop hub/rotor and loosen nut to completely release
bearing preload torque. Tighten the nut finger-tight and
install the nut lock. Install a new cotter pin. Fig. 7 Lower Bail Stud Removal
(7) The adjustment (above) should have 0.001 to ASSEMBLY
0.003 inch (0.254 to 0.0762 mm) end play. (1) Press replacement ball stud into the lower sus
(8) Clean the dust cap and apply a coating lubri pension arm bore with special tools (Fig. 8).
cant to the internal surface. Do not f i l l the dust (2) Install lower suspension arm.
cap with lubricant. Install the cap.
(9) Install disc brake caliper, refer to Group 5
Brakes.
(10) Install the wheel and tire assembly.
WHEEL STUDS
REMOVAL
(1) Remove wheel and tire assembly.
(2) Remove disc brake rotor, refer Group 5 Brakes.
(3) Place rotor on flat surface and drive studs out SPECIAL TOOL
C-4212F
of the with a hammer and punch.
INSTALLATION
(1) Turn the rotor over and place in a vise.
(2) Drive new studs into the rotor with hammer
and punch.
(3) Install rotor, refer to Group 5 Brakes.
(4) Install wheel and tire assembly.
DISASSEMBLY AND ASSEMBLY
LOWER BALL STUD
DISASSEMBLY 6761 J9402-34

(1) Remove lower suspension arm.
Fig. 8 Lower Ball Stud Installation
BR SUSPENSION 2 -13
D I S A S S E M B L Y AND A S S E M B L Y ( C o n t i n u e d )
UPPER 1ALL STUD
DISASSEMBLY
(1) Remove the upper suspension arm. SPECIAL TOOL
(2) Position special tools on upper suspension arm C4212F
and press ball stud out of arm (Fig. 9).
SPECIAL TOOL
C-4212F
J9402-35
Fig. 10 Upper Ball Stud Installation

SPECIFICATIONS
IFS SUSPENSION (WAX COAT FRAME)

SPECIAL TOOL
6289-3 J9402-36 DESCRIPTION TORQUE
Shock Absorber
Fig. 9 Upper Bail Stud Removal Upper Nut. . . . . . . . .41 N-m (30 ft. lbs.)
ASSEMBLY Lower Bolt. .135 N-m (100 ft. lbs.)
(1) Press ball stud into upper suspension arm with Lower Suspension Arm
special tools (Fig. 10). Frame Nuts 149 N-m (110 ft. lbs.)
(2) Install the upper suspension arm. Ball Stud Nut 75 N-m (55 ft. lbs.)
Upper Suspension Arm
Pivot Bar Nuts . . . . . . . .203 N-m (150 ft. lbs.)
C L E A N I N G AND INSPECTION Ball Stud Nut . . . . . . . 75 N-m (55 ft. lbs.)
Stabilizer Bar
WHEEL BEAR1NSS • Clamp Bolt . . .47 N-m (35 ft. lbs.)
Link Nuts 34 N-m (25 ft. lbs.)
NOTE: Bearing and races must be replaced as a
IFS SUSPENSION (E-C0AT FRAME)
set if worn or damaged.
(1) Thoroughly clean the interior of hub/rotor. DESCRIPTION TORQUE

(2) Clean the bearings with solvent and towel dry. Shock Absorber
(3) After cleaning, apply engine oil to each bear Upper Nut 41 N-m (30 ft. lbs.)
Lower Bolt. 135 N-m (100 ft. lbs.)
ing.
Lower Suspension Arm
(4) Rotate each bearing slowly while applying
Frame Nuts .271 N-m (200 ft. lbs.)
downward force. Examine the rollers for pitting and Ball Stud Nut 75 N-m (55 ft. lbs.)
roughness, replace bearing i f worn or defective. Upper Suspension Arm
(5) Remove the engine oil from each bearing. Pack Pivot Bar Nuts 271 N-m (200 ft. lbs.)
each bearing with multi-purpose NLGI, grade 2, EP- Ball Stud Nut 75 N-m (55 ft. lbs.)
type lubricant (or an equivalent lubricant). Stabilizer Bar
Clamp Bolt . .61 N-m (45 ft. lbs.)
NOTE: Ensure that lubricant is forced into all the Link Nuts 34 N-m (25 ft. lbs.)
cavities between the bearing cage and rollers.
2 - 14 SUSPENSION
SPECIAL TOOLS
Installer, Ball Stud 6761

BR SUSPENSION 2 - 15
FRONT SUSPENSION L I N K / C O I L
INDEX
page page
GENERAL INFORMATION STEERING KNUCKLE 17

FRAME COATINGS INFORMATION 15 TRACK BAR 18
DESCRIPTION AND OPERATION UPPER SUSPENSION ARM 17
FRONT SUSPENSION LINK/COIL 15 WHEEL HUB/BEARING 18
DIAGNOSIS AND TESTING WHEEL MOUNTING STUDS 19
SHOCK DIAGNOSIS . .* 16 SPECIFICATIONS
REMOVAL AND INSTALLATION LINK/COIL SUSPENSION (E-COAT FRAME) 19
COIL SPRING 17 LINK/COIL SUSPENSION (WAX COAT FRAME) . 19
LOWER SUSPENSION ARM 17 SPECIAL TOOLS
SHOCK ABSORBER 16 LINK/COIL SUSPENSION 20
STABILIZER BAR 18
G E N E R A L INFORMATION © Stabilizer bar

• Track bar
FRAME COATINGS INFORMATION
CAUTION: Depending on the vehicle build location,

there are two different coatings applied to BR
frames:
11th
VEHICLE
POSITION FRAME
BUILD
VIN COATINC
LOCATION
CHARACTER
Saltillo Mexico G Wax Coat
Lago Alberto M Wax Coat
Mexico
Fig. 1 Link/Coil Suspension
Replacement fasteners and torque values for Shock Absorbers: The shock absorbers dampen
frame attached components may vary depending on the jounce and rebound of the vehicle over various
frame coatings. Ensure the replacement fastener is road conditions. Shocks are mounted inside the
designed for the specific frame coating. Refer to the springs and attached at the top to brackets with
Torque Specifications Chart at the end of each grommets. These brackets are bolted on the frame
group to determine the correct torque value. with three studs on a ring. The shock is mounted at
the bottom of the axle below the spring seat.
Coil Springs: The coil springs control ride quality
DESCRIPTION AND OPERATION and maintain proper ride height. The springs use a
rubber isolators between the frame bracket and
FRONT SUSPENSION LINK/COIL spring. The isolators help prevent road noise. The
The Ram Truck Link/coil suspension allows each bottom of the spring sits on a seat mounted to the
wheel to adapt to different road surfaces. The sus axle.
pension is comprized of (Fig. 1); Suspension Arms: The upper and lower suspen
© Shock absorbers sion arms use bushings to isolate road noise. The
© Coil springs suspension arms are bolted to the frame and axle
• Upper and lower suspension arms through the rubber bushings. The lower suspension
arm uses cam bolts at the axle to allow for caster
and pinion angle adjustment. The suspension arm
travel (jounce or rebound) is limited through the use
of urethane bumpers.
Stabilizer Bar: The stabilizer bar is used to min
imize vehicle front sway during turns. The spring
steel bar helps to control the vehicle body in relation
ship to the suspension. The bar extends across the
front underside of the chassis and connects to the
frame rails. Links are connected from the bar to the
axle brackets. Stabilizer bar mounts are isolated by
teflon lined rubber bushings.
Track Bar: The track bar is used to minimize
front axle side-to-side movement. The bar is attached
to a frame rail bracket with a ball stud and is iso
lated with a bushing at the axle bracket.
Steering Knuckles: The steering knuckles pivot
on replaceable ball studs attached to the axle tube
yokes.
NOTE: Suspension components which use rubber

bushings should be tightened at vehicle ride height. J9402-46
This will prevent premature failure of the bushing
and maintain ride comfort. Bushings must never be Fig. 2 Shock Absorber and Bracket
lubricated.
(3) Remove the lower bolt from the axle bracket
(Fig. 3). Remove the shock absorber from engine com
partment.
SHOCI DIAGNOSIS
A noise from a shock absorber may be caused by
movement between mounting bushings and metal
brackets or attaching components. This noise can
usually be stopped by tightening the attaching nuts.
If the noise persists, inspect for damaged and worn
bushings, and attaching components. Repair as nec
essary i f any of these conditions exist.
The shock absorbers are not refillable or adjust
able. I f a malfunction occurs, the shock absorber
must be replaced. To test a shock absorber, hold it in
an upright position and force the piston in and out of
the cylinder four or five times. The action throughout
each stroke should be smooth and even.
The shock absorber bushings do not require any
type of lubrication. Do not attempt to stop bushing
noise by lubricating them. Grease and mineral oil- SHOCK BOLT
base lubricants will deteriorate the bushing rubber.
J9402-47
REMOVAL AND INSTALLATION
Fig. 3 Shock Absorber Axle Mount
SHOCK ABSORBER INSTALLATION
(1) Position the lower retainer and grommet on the
REMOVAL upper stud. Insert the shock absorber through the
(1) Remove the nut, retainer and grommet from spring from engine compartment.
the upper stud in the engine compartment. (2) Install the lower bolt and tighten bolt to speci
(2) Remove three nuts from the upper shock fications.
bracket (Fig. 2).
BR SUSPENSION 2 -17
R E M O V A L A H P I N S T A L L A T I O N {Continued)
(3) Install the upper shock bracket and three nuts. LOWER SUSPENSION A R 1
Tighten nuts to specifications.
(4) Install upper grommet and retainer. Install REMOVAL
upper shock nut and tighten to specifications. (1) Raise and support the vehicle.
(2) Paint or scribe alignment marks on the cam
COIL SPRING adjusters and suspension arm for installation refer
ence (Fig. 4).
REMOVAL
y ADJUSTMENT i
(1) Raise and support the vehicle. Position a t
hydraulic jack under the axle to support it.

(2) Paint or scribe alignment marks on lower sus
pension arm cam adjusters and axle bracket for
installation reference.
(3) Remove the upper suspension arm and loosen
lower suspension arm bolts.
(4) Mark and disconnect the front propeller shaft
from the axle 4x4 models.
(5) Disconnect the track bar from the frame rail
bracket.
(6) Disconnect the drag link from pitman arm.
(7) Disconnect the stabilizer bar link and shock
absorber from the axle.
(8) Lower the axle until the spring is free from the
upper mount. Remove the coil spring.
INSTALLATION
(1) Position the coil spring on the axle pad.
(2) Raise the axle into position until the spring
seats in the upper mount. J9302-59
(3) Connect the stabilizer bar links and shock

absorbers to the axle bracket. Connect the track bar Fig. 4 Cam Adjuster
to the frame rail bracket. (3) Remove the lower suspension arm nut, cam
(4) Install the upper suspension arm. and cam bolt from the axle.
(5) Install the front propeller shaft to the axle 4x4 (4) Remove the nut and bolt from the frame rail
model. bracket and remove the lower suspension arm (Fig.
(6) Install drag link to pitman arm and tighten 5).
nut to specifications. Install new cotter pin.
(7) Remove the supports and lower the vehicle. INSTALLATION
(8) Tighten the following suspension components (1) Position the lower suspension arm at the axle
to specifications: bracket and frame rail bracket.
• Link to stabilizer bar nut. (2) Install the rear bolt and finger tighten the nut.
• Lower shock bolt. (3) Install the cam bolt, cam and nut in the axle.
• Track bar bolt at axle shaft tube bracket. Re-align the reference marks.
® Upper suspension arm nut at axle bracket. (4) Remove support and lower the vehicle.
® Upper suspension nut at frame bracket. (5) Tighten cam nut to specifications. Tighten rear
• Align lower suspension arm reference marks and nut to specifications.
tighten cam nut.
• Lower suspension nut at frame bracket. UPPER SUSPENSION ARWI
STEERING KNUCKLE REMOVAL

For service procedures on the steering knuckle and (1) Raise and support the vehicle.
ball studs refer to Group 3 Differentials And Driv- (2) Remove the upper suspension arm nut and bolt
eline. at the axle bracket (Fig. 5).
(3) Remove the nut and bolt at the frame rail and
remove the upper suspension arm.
2 -18 SUSPENSION BR
REMOVAL AND INSTALLATION (Continued)
SHOCK ABSORBER
centered with equal spacing on both sides. Tighten
STABILIZER
BAR
the bolts to specifications.
COIL SPRING (2) Install the links, grommets retainers and nuts
UPPER onto the axle brackets. Tighten the nuts to specifica
SUSPENSION tions.
ARM
(3) Install link on stabilizer bar and tighten nut to
specifications.
(4) Remove the supports and lower the vehicle.
TRACK BAR
REMOVAL
LOWER < (2) Remove the cotter pin and nut from the ball
TRACK
SUSPENSION
BAR stud end at the frame rail bracket (Fig. 7).
ARM J9402-54
(3) Remove ball stud from bracket with Puller
Fig, 5 Upper and Lower Suspension Arm C-3894-A
(4) Remove the bolt and flag nut from the axle
INSTALLATION
bracket and remove the track bar (Fig. 7).
(1) Position the upper suspension arm at the axle
and frame rail. AXLE
(2) Install the bolts and finger tighten the nuts. BRACKET
(4) Tighten nut at the axle bracket to specifica
tions. Tighten nut at frame bracket to specifications.
STABILIZER BAR fify FRAME

BRACKET
REMOVAL
(2) Disconnect the stabilizer bar links from the
axle brackets.
(3) Disconnect the stabilizer bar from the links.
(4) Disconnect the stabilizer bar clamps from the TRACK BAR
frame rails and remove the stabilizer bar (Fig. 6). FLAG NUT J9402-53
STABILIZER RETAINER Fig. 7 Track Bar

BAR
INSTALLATION
(1) Install the track bar at axle tube bracket.
GROMMET Loosely install the retaining bolt and flag nut.
(2) Pry the axle assembly over to install the track
bar at the frame rail bracket.
GROMMET (3) Install the retaining nut on the stud. Tighten
the ball stud nut to specifications. Install a new cot
ter pin.
RETAINER
(5) Tighten the bolt at the axle shaft tube bracket
LINK to specifications.
J9402-52 WHEEL HUB/BEARING
Fig. 6 Stabilizer Bar REMOVAL

INSTALLATION (2) Remove wheel and tire assembly.
(1) Position the stabilizer bar on the frame rail (3) Remove brake caliper and rotor, refer to Group
and install the clamps and bolts. Ensure the bar is 5 Brakes.
(4) Remove cotter pin and axle hub nut.
BR - - SUSPENSION 2 -19

( 5 ) Remove hub/bearing mounting bolts (Fig. 8) INSTALLATION
and remove hub/bearing from knuckle. (1) Install new stud into hub flange.
(2) Install three washer onto stud, then install lug
nut with the flat side of the nut against the washers.
(3) Tighten lug nut until the stud is pulled into
the hub flange. Verify that the stud is properly
seated into the flange.
(4) Remove lug nut and washers.
(5) Install the brake rotor and caliper, refer to
Group 5 Brakes for procedure.
(6) Install wheel and tire assembly, use new lug
nut on stud or studs that were replaced.
SPECIFICATIONS
BEARING
J9402-58 LINK/COIL SUSPENSION (WAX COAT FRAME)
Fig. 8 Hub/Bearing & Knuckle DESCRIPTION TORQUE •

Shock Absorber
INSTALLATION
Upper Nut 41 N-m (30 ft. lbs.)
(1) Install hub/bearing and tighten mounting bolts
Lower Bolt. 135 N-m (100 ft. lbs.)
to specifications. Bracket . . . . 75 N-m (55 ft. lbs.)
(2) Install axle hub nut and tighten to specifica Suspension Arm Upper
tions. Install cotter pin. Axle Nut .121 N-m (89 ft. lbs.)
(3) Install brake rotor and caliper, refer to Group 5 Frame Nut . . . . . . . . . . . . .84 N-m (62 ft. lbs.)
Brakes. Suspension Arm Lower
(4) Install wheel and tire assembly. Axle Nut . .149 N-m (110 ft. lbs.)
(5) Remove support and lower vehicle. Frame Nut. .122 N-m (90 ft. lbs.)
Stabilizer Bar
WHEEL MOUNTING STUDS Clamp Bolt 47 N-m (35 ft. lbs.)
Link Upper Nut. .37 N-m (27 ft. lbs.)
REMOVAL Link Lower Nut. . . 118 N-m (87 ft. lbs.)
(1) Raise and support vehicle. Track Bar
(2) Remove wheel and tire assembly. Ball Stud Nut . . . 84 N-m (62 ft. lbs.)
(3) Remove brake caliper and rotor, refer to Group Axle Bracket Bolt . . . . .176 N-m (130 ft. lbs.)
5 Brakes for procedure.
LINK/COIL SUSPENSION (E-C0AT FRAME)
(4) Remove stud from hub with Remover C-4150A
(Fig. 9).
DESCRIPTION TORQUE
Shock Absorber
HUB F L A N G E Upper Nut 41 N-m (30 ft. lbs.)
REMOVER
Lower Bolt. . . . . . . . . . .135 N-m (100 ft. lbs.)
Bracket 75 N-m (55 ft. lbs.)
Suspension Arm Upper
Axle Nut . . . . . . . . . . . . . . . . .121 N-m (89 ft. lbs.)
Frame Nut .149 N-m (110 ft. lbs.)
Suspension Arm Lower
Axle Nut . .149 N-m (110 ft. lbs.)
Frame Nut. .217 N-m (150 ft. lbs.)
Stabilizer Bar
Clamp Bolt .. . . . . . .61 N-m (45 ft. lbs.)
Link Upper Nut .37 N-m (27 ft. lbs.)
Link Lower Nut. 118 N-m (87 ft. lbs.)
Track Bar
Ball Stud Nut .84 N-m (62 ft. lbs.)
Axle Bracket Bolt . . . . . . . . .176 N-m (130 ft. lbs.)
Fig. 9 Wheel Stud Removal
2 - 20 SUSPENSION
SPECIAL TOOLS
LINK/COIL SUSPENSION
Remover C-4150A
REAR SUSPENSION
INDEX
page page
GENERAL INFORMATION REMOVAL AND INSTALLATION

WEIGHT DISTRIBUTION 21 LEAF SPRING .... 22
DESCRIPTION AND OPERATION SHOCK ABSORBER 22
SUSPENSION COMPONENT 21 SPECIFICATIONS
DIAGNOSIS AND TESTING REAR SUSPENSION (E-COAT FRAME) 23
SPRING AND SHOCK DIAGNOSIS 21 REAR SUSPENSION (WAX COAT FRAME) . . . . 23
GENERAL INFORMATION body and is attached to the body rails with grom-
mets. Links at the end of the bar are attached to the
WEIGHT DISTRIBUTION leaf spring brackets.
A vehicle should always be loaded so the vehicle Jounce Bumpers: The'jounce bumpers are used
weight center-line is located immediately forward of to limit the spring and axle travel. They are bolted to
the rear axle. Correct vehicle loading provides proper the body rail above the axle.
front tire-to-road contact. This results in maximum
vehicle handling stability and safety. Incorrect vehi NOTE; Suspension components that use rubber
cle weight distribution can cause excessive tire tread bushings should be tightened with the vehicle at
wear, spring fatigue or failure, and erratic steering. the normal height. Rubber bushings must never be
lubricated.

SUSPENSION COMPONENT
The rear suspension is comprised of: SPRING AND SHOCK OJAONOSIS
® Drive Axle
A noise from a shock absorber may be caused by
© Leaf Springs
movement between mounting bushings and metal
• Dual-Action Shock Absorbers
bracket or attaching components. This noise can usu
• Stabilizer Bar
ally be stopped by tightening the attaching nuts. I f
• Jounce Bumpers
the noise persists, inspect for damaged and worn
Leaf Springs: The rear suspension system uses a
bushings, and attaching components. Repair as nec
multi-leaf springs and a solid drive axle. The forward
essary i f any of these conditions exist.
end of the springs are mounted to the body rail hang
The shock absorbers are not refillable or adjust
ers through rubber bushings. The rearward end of
able. I f a malfunction occurs, the shock absorber
the springs are attached to the body by the use of
must be replaced. To test a shock absorber, hold it in
shackles. The spring and shackles use rubber bush
an upright position and force the piston in and out of
ings. The bushing help to isolate road noise. The
the cylinder four or five times. The action throughout
shackles allow the springs to change their length as
each stroke should be smooth and even.
the vehicle moves over various road conditions.
The spring eye and shock absorber bushings do not
Shock Absorbers: Ride control is accomplished
require any type of lubrication. Do not attempt to
through the use of dual-action shock absorbers. The
stop spring bushing noise by lubricating them.
shocks dampen the jounce and rebound as the vehicle
Grease and mineral oil-base lubricants will deterio
travels over various road conditions. The top of the
rate the bushing rubber.
shock absorbers are bolted to the body crossmember.
I f the vehicle is used for severe, off-road operation,
The bottom of the shocks are bolted to the axle
the springs should be examined periodically. Check
bracket.
for broken and shifted leafs, loose and missing clips,
Stabilizer Bar: The stabilizer bar is used to min
and broken center bolts. Refer to Spring and Shock
imize vehicle body roll. The spring steel bar helps to
Absorber Diagnosis chart for additional information.
control the vehicle body in relationship to the sus
pension. The bar extends across the underside of the
SPRING AND SHOCK nttSUHBER DIAGNOSIS
SPRING SAGS 1. Broken leaves 1. Replace broken leaves
2. Spring fatigue 2. Replace spring
SPRING NOISE 1. Loose U-bolts 1. Tighten U-bolts to specified torque
2 Worn bushings 2. Replace bushings
3. Worn or missing leaf liners 3. Replace leaf liners
SHOCK ABSORBERS 1. Loose mounting bolt or nut 1. Tighten bolt or nut to specified torque
NOISY
2. Worn bushings 2. Replace shock absorber
3. Leaking shock 3. Replace shock
J9503-2
REMOVAL AND INSTALLATION (3) Remove the nuts and bolts from the spring
front and rear shackle eyes. Note: To remove front
SHOCK ABSORBER eye bolt on left side spring fuel tank must be
removed, refer to Group 14 for fuel tank proce
REMOVAL dure.
(1) Raise vehicle and support axle. (4) Remove spring from vehicle.
(2) Remove the bolt and flag nut from the frame (5) Remove shackle from spring.
crossmember bracket.
(3) Remove the bolt and nut from the axle bracket.
(4) Remove the rear shock absorber from the vehi
cle.
INSTALLATION
(1) Position shock absorber in brackets.
(2) Install bolts through the brackets and shock.
Install flag nut on top bolt and nut on lower bolt.
(3) Tighten upper and lower bolts to specifications
(4) Remove the support and lower vehicle.
LEAF SPRING
REMOVAL
(1) Raise vehicle and support axle to remove all
weight from springs.
Fig. 1 Rear Spring—4X2
(2) Remove the nuts and spring clamp bolts that
attach the spring to the axle (Fig. 1) and (Fig. 2) and
(Fig. 3).
REMOVAL AND INSTALLATION (Continued!

SPRING CLAMP (6) Install spring clamp bolts and the retaining
BOLT SPRING SEAT nuts.
(7) Align the auxiliary spring with the primary
spring i f equipped. Tighten the nuts, until they force
the plate flush against the axle tube.
(8) Remove the supports and lower the vehicle so
that the weight is being supported by the tires.
SPRING (9) Tighten the spring clamp retaining nuts to
specifications
SPACER (10) Tighten spring front and rear eye pivot bolt
nuts and shackle eye to specifications.
SPRING PLATE
SPECIFICATIONS
SHACKLE' J9403-61 REAR SUSPENSION (WAX COAT FRAME)
Fig. 2 Rear Spring—4X4 DESCRIPTION TORQUE

SPRING CLAMP
Shock Absorber
BOLT SPRING SEAT Lower Nut .136 N-m (100 ft. lbs.)
Upper Nut . . . . . . . . .95 N-m (70 ft. lbs.)
Spring Clamp Nuts
AUXILIARY SPRING 6,010-10,500 GVW . . . . . . . . .149 N-m (110 ft. lbs.)
11,000 GVW Cab-Chassis . . .163 N-m (120 ft. lbs.)
Spring Front and Rear Eye
SPRING Bolt/Nut 6,010-7,500 GVW. . .203 N-m (150 ft. lbs.)
Bolt/Nut 8,800-1,100 GVW. . .285 N-m (210 ft. lbs.)
SPACER Jounce Bumper
Bolts 45 N-m (33 ft. lbs.)
REAR SUSPENSION (E-C0AT FRAME)
SPRING PLATE
SHACKLE' J9403-62 DESCRIPTION TORQUE

Shock Absorber
Fig. 3 Rear Spring—Cab-Chassis 11000 GVW Lower N u t . . . . . . . . . . . 136 N-m (100 ft. lbs.)
Upper N u t . . . . . . . . . . .149 N-m (110 ft. lbs.)
INSTALLATION
Spring Clamp Nuts
(1) Install shackle on rear spring eye and install
bolt and nut. 6,010-10,500 GVW . . . . . . . . .149 N-m (110 ft. lbs.)
(2) Position spring on axle shaft tube so spring 11,000 GVW Cab-Chassis . . .163 N-m (120 ft. lbs.)
center bolt is inserted into the locating hole in the Spring Front and Rear Eye
axle tube spring pad or spacer. Bolt/Nut 6,010-7,500 GVW. . .203 N-m (150 ft. lbs.)
(3) Align spring front eye with bolt hole in the Bolt/Nut 8,800-1,100 GVW. .2271 N-m (200 ft. lbs.)
front bracket. Install the eye pivot bolt and nut. Jounce Bumper
(4) Align shackle eye with bolt hole i n rear Bolts 61 N-m (45 ft. lbs.)
bracket. Install bolt and nut.
(5) Tighten the spring front and rear eye pivot bolt
snug do not torque.
DIFFERENTIAL AND DRIVELINE 3 -1
DIFFERENTIAL AND DRIVELINE

CONTENTS
I t i
page page
FRONT AXLE—MODEL 44/60 15 PROPELLER SHAFTS 1

MODEL 60/70/80 AXLES 79 REAR AXLE—MODEL 9 1/4 51
PROPELLER SHAFTS
INDEX
page page
G E N E R A L INFORMATION REAR PROPELLER SHAFT . . . . . . . . . . . . . . . . . 7

CENTER BEARING 2 T W O PIECE PROPELLER SHAFT—REAR . . . . . . 8
LUBRICATION 2 DISASSEMBLY AND ASSEMBLY
PRECAUTIONS 2 CENTER BEARING 8
PROPELLER SHAFTS 1 DOUBLE CARDAN (CV) 10
UNIVERSAL JOINTS 2 SINGLE CARDAN . 9
DIAGNOSIS AND TESTING CLEANING AND INSPECTION
RUNOUT 4 SINGLE AND DOUBLE CARDAN JOINT . . . . . . . 13
UNBALANCE 3 ADJUSTMENTS
VIBRATION 3 ADJUSTMENT AT AXLE W I T H LEAF SPRINGS . 1 4
SERVICE PROCEDURES CENTER BEARING ADJUSTMENT—TWO
INSPECTION 5 PIECE SHAFT 14
MEASUREMENT—TWO-PIECE SHAFT 6 SPECIFICATIONS
PROPELLER SHAFT ANGLE MEASUREMENT . . . 5 TORQUE . . . . . . . . . . 14
UNIVERSAL JOINT ANGLE 4 SPECIAL TOOLS
REMOVAL AND INSTALLATION PROPELLER SHAFT . . . . . . . . . . . . . . . . . 14
FRONT PROPELLER SHAFT 7
GENERAL INFORMATION Tubular propeller shafts are balanced by the man

ufacturer with weights spot welded to the tube.
PROPELLER SHAFTS The propeller shaft is designed and built with the
The function of a propeller shaft is to transmit yoke lugs in line with each other which is called
power from one point to another in a smooth action. phasing. This design produces the smoothest running
The shaft is designed to send torque through an condition. An out of phase shaft can cause a vibra
angle from the transmission (transfer case on 4WD tion.
vehicles) to the axle. Before undercoating a vehicle, the propeller
The propeller shaft must operate through con shaft and the U-joints should be covered. This
stantly changing relative angles between the trans will prevent the undercoating from causing an
mission and axle. I t must also be capable of changing out of balance condition and vibration.
length while transmitting torque. The axle rides sus
pended by springs in a floating motion. This means CAUTION: Use exact replacement parts for attach
the propeller shaft must be able to change angles ing the propeller shafts. This will ensure safe oper
when going over various roads. This is accomplished ation. The specified torque must always be applied
through universal joints, which permit the propeller when tightening the fasteners.
shaft to operate at different angles. The slip joints (or
yokes) permit contraction or expansion.
3 -2 DIFFERENTIAL AND DRIVELINE BR
CENTER BEARING
The two-piece propeller shaft uses a center bearing
to support the shafts. Two types of center bearings
are used. Type 1 is used with the 9 1/4 axle. Type 2
is used with the Dana axles (Fig. 1). Both types are
mounted in the same location.
RETAINER J9416-11
TYPE 2 TYPE 1 Fig. 2 Single Cardan Universal Joint—Typical

— J9416-2
Fig. 1 Center Bearing S LINK YOKE
UNIVERSAL JOINTS
The front prop shaft uses a 7290 series universal
joints. The rear prop shaft uses a 7290 series univer
sal joint with a 9 1/4 axle. A 1410 series universal
joint is used with the Dana 60, 70 and 80 rear axles.
Shaft with 7290 series universal joints use external
snap rings. Shafts with 1410 series universal joints
use internal snap rings.
Two different types of universal joints systems are
used:
® Single cardan universal joint (Fig. 2)
• Double cardan universal joint (Fig. 3)
LUliiCATlON
The slip yoke on the Type 1 front shaft is equipped
with a lubrication fitting. Use a multi-purpose NLGI
Grade 2 EP lubricant.The factory installed U-joints
are lubricated for the life of the vehicle and do not
need lubrication. All U-joints should be inspected for
leakage and damage each time the vehicle is ser
viced. I f seal leakage or damage exists, the U-joint
should be replaced.
PRECAUTIONS
Use exact replacement hardware for attaching the
propeller shafts. Exact replacement will ensure safe
operation. The specified torque must always be
applied when tightening the fasteners.
Put reference marks on the propshaft yoke and
J9316-2
axle or transmission yoke before service (Fig. 4). This
will assure correct phasing and eliminate possible Fig. 4 Reference Marks on Yokes
vibration.
DIFFERENTIAL AND DRIVELINE 3-3
CAUTION: Do not allow the propeller shaft to drop UNBALANCE
or hang from either universal joint during removal If propeller shaft unbalance is suspected, i t can be
Attach it to the vehicle underside with wire to pre verified with the following procedure:
vent damage to the universal joints. Removing and re-indexing the propeller shaft
180° may eliminate some vibrations.
• Clean all the foreign material from the propeller
CAUTION: It is very important to .protect the
shaft and the universal joints.
machined, external surface of the slip yoke from
• Inspect the propeller shaft for missing balance
damage after propeller shaft removal, if damaged,
weights, broken welds, and bent areas. If the pro
the transmission extension seal could be damaged
peller shaft is bent, it must be replaced.
and cause a leak.
• Ensure the universal joints are not worn, are
properly installed, and are correctly aligned with the
shaft.
DIAGNOSIS AND T E S T I N G • Check the universal joint clamp screws torque
(1) Raise the vehicle.
VIBRATION (2) Remove the wheel and tires assembly. Install
Tires that are out-of-round or wheels that are the wheel lug nuts to retain the brake drums.
unbalanced will cause a low frequency vibration. (3) Mark and number the shaft six inches from the
Refer to Group 22, Wheels and Tires for additional yoke end at four positions 90° apart.
information. (4) Run and accelerate the vehicle until vibration
Brake drums that are unbalanced will cause a occurs. Note the intensity and speed the vibration
harsh, low frequency vibration. Refer to Group 5, occurred. Stop the engine.
Brakes for additional information. (5) Install a screw clamp at position 1 (Fig. 5).
Driveline vibration can also result from loose or (6) Start the engine and re-check for vibration. I f
damaged engine mounts. Refer to Group 21, Trans there is little or no change in vibration, move the
missions for additional information. clamp to one of the other three positions. Repeat the
Propeller shaft vibration will increase as the vehi vibration test.
cle speed is increased. A vibration that occurs within (7) I f there is no difference in vibration at the
a specific speed range is not caused by propeller other positions, the vibration may not be propeller
shaft unbalance. Defective universal joints or an shaft unbalance.
incorrect propeller shaft angle are usually the cause. (8) I f the vibration decreased, install a second
clamp (Fig. 6) and repeat the test.
DRIVELINE VIBRATION
D r i v e Condition Possible Cause Correction
PROPELLER SHAFT a. Undercoating or other foreign material a. Clean exterior of shaft and wash with
on shaft. solvent.
b. Loose U-joint clamp screws. b. Tighten screws properly.
c. Loose or bent U-joint yoke or excessive c. Install replacement yoke.
runout.
d. Incorrect drive line angularity. d. Correct angularity
e. Rear spring center bolt not in seat. e. Loosen spring U-bolts and seat center
bolts.
f. Worn U-joint bearings. f. Replace U-joint.
g. Propeller shaft damaged (bent tube) or g. Install replacement propeller shaft.
out of balance.
h. Broken rear spring. h. Replace rear spring.
i. Excessive runout or unbalanced i. Reindex propeller shaft 180°, test and
condition. correct as necessary.
j. Excessive drive pinion gear shaft yoke j . Reindex propeller shaft 180° and
runout. evaluate.
UNIVERSAL JOINT NOISE a. U-joint clamp screws loose. a. Tighten screws with specified torque.
b. Lack of lubrication. b. Replace U-joint.
mi 6-7
3 -4 DIFFERENTIAL AND DRIVELINE — ——^ —^ BR
D I A G N O S I S A N D T E S T I N G (Continued)
(10) Increase distance between the clamp screws
and repeat the test until the amount of vibration is
at the lowest level. Bend the slack end of the clamps
so the screws will not loosen.
: (11) Install the wheel and tires. Lower the vehicle.
(12) I f the amount of vibration remains unaccept
able, apply procedures at the front end of the propel
ler shaft.
RUNOUT
(1) Remove dirt, rust, paint, and undercoating
from the propeller shaft surface. Areas where the dial
indicator will contact the shaft must be clean.
(2) The dial indicator must be installed perpendic
ular to the shaft surface.
(3) Measure runout at the center and ends away
Fig. 5 Clamp Screw At Position 1 from welds.
(4) Refer to Runout Specifications chart.
(5) Replace the propeller shaft i f the runout
exceeds the limit.
RUNOUT SPECIFICATIONS
Front of shaft 0.010 in. (0.25 mm)
Center of shaft . . .". . . . . . . 0.015 in. (0.38 mm)
Rear of shaft . . . . . . ,, 0.010 in. (0.25 mm)
NOTE: Measure front/rear runout approximately 3 inches

(76 mm) from the weld seam at each end of the shaft tube
for tube lengths over 30 inches. Under 30 inches the max.
runout is 0.20 inch for full length of the tube.
RF488
J9116-15
Fig. 6 Two Clamp Screws At The Same Position
SERVICE PROCEDURES
(9) I f the clamps cause an additional unbalance,
separate the clamps (1/4 inch above and below the
UNIVERSAL JOINT ANGLE
mark). Repeat the vibration test (Fig. 7).
INFORMATION
When two shafts come together at any common
joint, the bend that is formed is called the operating
angle. The larger the angle, the larger the amount of
acceleration and deceleration of the joint. This speed
ing up and slowing down of the joint must be can
celled to produce a smooth power flow. This is done
through phasing and proper universal joint working
angles.
A propeller shaft is properly phased when the yoke
ends are on the same plane or in line. A twisted shaft
will throw the yokes out of phase and cause a notice
able vibration.
When taking universal joint angle measurements
1 or checking phasing with two piece shafts, consider
each shaft separately. On 4WD vehicles, the front
Fig. 7 Clamp Screws Separated shaft input (pinion shaft) angle has priority over the
caster angle.
Ideally the driveline system should have;
BR DIFFERENTIAL AND DRIVELINE 3-5
SERVICE PROCEDURES ( C o n t i n u e d )
• Angles that are in equal or opposite within 1
degree of each other
• Have a 3 degree maximum operating angle
• Have at least a 1/2 degree continuous operating
(propeller shaft) angle
Engine speed (rpm) is the main factor though in
determining maximum allowable operating angles.
As a guide to maximum normal operating angles
refer to the chart listed (Fig. 8).
PROPELLER SHAFT M A X « NORMAL

R.P.M. OPERATING ANGLES
5000 3°
4500 3°
4000 4°
3500 5°
3000 5°
2500 7°
2000 8°
1500 11°
J9316-4 (J-23498A) J9216-13
Fig. 9 Front (Output) Angle Measurement (A)

Fig. 8 Maximum Angles And Engine Speed
measurement. This measurement can also be taken
INSPECTION at the rear end of the shaft.
Before measuring universal joint angles, the This measurement will give you the Propeller
following must be done. Shaft Angle (C).
• Inflate all tires to correct pressure
• Check angles in the same loaded or unloaded
condition as when the vibration occurred. Propeller
shaft angles will change according to the amount of
load in the vehicle. Always check angles in loaded
and unloaded conditions.
• * Check the condition of all suspension compo
nents and verify all fasteners are torqued to specifi
cations.
• Check the condition of the engine and transmis
sion mounts and verify all fasteners are torqued to
specifications.
PROPELLER SHAFT ANGLE MEASUREMENT

To accurately check driveline alignment, raise and
support the vehicle at the axles as level as possible.
Allow the wheels and propeller shaft to turn. Remove
any external bearing snap rings (if equipped) from
universal joint so protractor base sits flat. J9216-9
(1) Rotate the shaft until transmission/transfer
case output yoke bearing is facing downward. Fig. 10 Propeller Shaft Angle Measurement (C)
Always make measurements from front to
(4) Subtract smaller figure from larger (C minus
rear.
A) to obtain Transmission Output Operating Angle.
(2) Place Inclinometer on yoke bearing (A) parallel
(5) Rotate propeller shaft 90 degrees and place
to the shaft (Fig. 9). Center bubble in sight glass and
Inclinometer on pinion yoke bearing parallel to the
record measurement.
shaft (Fig. 11). Center bubble in sight glass and
This measurement will give you the transmis
record measurement.
sion or Output Yoke Angle (A).
This measurement will give you the pinion
(3) Rotate propeller shaft 90 degrees and place
shaft or Input Yoke Angle (B).
Inclinometer on yoke bearing parallel to the shaft
(Fig. 10). Center bubble in sight glass and record
3 - i DIFFERENTIAL AND DRIVELINE BR
• Operating angles less than 3°
© At least 1/2 of one degree continuous operating
(propeller shaft) angle
MEASUREMENT—TWO-PIECE SHAFT
A rear propeller shaft U-joint angle can be easily
measured with Special Tool 7663.
The front half-shaft must be parallel to the rear
axle pinion gear shaft. The front and rear half-shafts
must be offset by a minimum of 1/2 of .a degree. From
the transmission/transfer case output shaft and from
each other.
To accurately check driveline alignment, raise and
support the vehicle at the axles as level as possible.
PINION YOKE
BEARING CAP Allow the wheels and propeller shaft to turn. Remove
any external bearing snap rings (if equipped) from
universal joint so protractor base sits flat.
SPECIAL (1) Rotate the shaft until transmission/transfer
TOOL
7663 case output yoke bearing is facing downward.
(J-23498A) J9216-12 (2) Place Inclinometer on yoke bearing (A) parallel
to the shaft (Fig. 13). Center bubble i n sight glass
Fig. 11 Rear (input) Angle Measurement (B) and record measurement.
(6) Subtract smaller figure from larger (C minus (3) Repeat measurement procedure on bearing cap
B) to obtain axle Input Operating Angle. B and C. Record these measurements.
Refer to rules given below and the example in (Fig. (4) Excessive variation in measurement angles of
12) for additional information. A, B or C indicate propeller mis-alignment. Vertical
• Good cancellation of U-joint operating angles alignment of a two-piece shaft at the yokes
(within 1°) should be greater t h a n one-half degree and as
close to one degree as possible.
Output
Yoke
Horizontal Level
(A) Output Yoke = 3.0° 4.9° (B) Axle Input Yoke 3.2° 4.9°
or
(C) Prop. Shaft r
= 4.9° ° - 3 . 0 ° (C) Prop. Shaft 4.9° -3.2°
Transmission Output 1 9° Axle Input 1.7°

Operating Angle Operating Angle
Trans. Output Operating Angle 1.9°

Axle Input Operating Angle -1.7°
Amount of U-J6int Cancellation 0.2°

J9316-3
Fig. 12 Universal Joint Angle Example

BR — — — DIFFERENTIAL AND DRIVELINE 3 -7
YOKES MUST BE IN SAME PLANE
J9016-26
Fig. 13 Universal Joint Angle—Two-Piece Shaft

REMOVAL AND INSTALLATION (3) Remove the U-joint strap bolts at the pinion
shaft yoke.
FRONT PROPELLER SHAFT (4) Remove bolts from transfer case yoke flange
and remove the propeller shaft.
REMOVAL
(1) Shift the transmission and transfer case to INSTALLATION
their neutral positions. Raise and support vehicle. (1) Position the propeller shaft with the yoke ref
Remove skid plates (if equipped), refer, to Group 13 erence marks aligned. Install the propeller shaft (Fig.
Frames. 14).
(2) Scribe alignment mark on transfer case and Replacement U-joint straps and bolts must be
propeller shaft flanges. Scribe mark on pinion shaft installed.
yoke and propeller shaft. These marks will be used (2) Tighten the U-joint strap bolts at the pinion
for installation reference (Fig. 14). shaft to 19 N-m (14 ft. lbs.) torque.
Tighten the transfer case bolts to 88 N-m (65 ft.
TRANSFER
CASE
lbs.) torque.
(3) Install skid plates (if equipped), refer to Group
13, Frames. Remove support and lower the vehicle.
REAR PROPELLER SHAFT
REMOVAL
(1) Shift the transmission and transfer case (if
applicable) to their Neutral positions. Raise and sup
port vehicle.
(2) Scribe alignment marks on the pinion yoke.
(3) Remove the U-joint strap bolts at pinion shaft
yoke.
(4) Slide the slip yoke off of the transmission/
STRAP transfer case output shaft and remove the propeller
shaft (Fig. 15).
INSTALLATION
(1) Slide the slip yoke on the transmission/transfer
SLIP YOKE AXLE
case output shaft. Align the installation reference
BOOT YOKE J9416-1 marks at the axle yoke and install the propeller shaft
(Fig. 15).
Fig. 14 Front Propeller Shaft Replacement U-joint straps and bolts must be
installed.
3 -8 DIFFERENTIAL AND DRIVELINE en
SLIDING (4) Scribe alignment marks on the frame cross-

member for center bearing reference. Remove bolts
that attach the center bearing to the support bracket
(Fig. 16).
(5) Slide the slip yoke off transmission output
shaft and remove the propeller shaft.
INSTALLATION
(1) Slide the slip yoke on transmission output
shaft. Align the installation reference marks at the
axle yoke.
(2) Align and install the center bearing to the sup
port bracket. Install the bolts and tighten to 68 N-m
(50 ft. lbs.) torque.
Replacement U-joint straps and bolts must be
installed.
(3) Tighten the U-joint strap bolts to;
• Dana Axle: 29 N-m (22 ft. lbs.) torque.
• 9 1/4 Axle: 19 N-m (14 ft. lbs.) torque.
SCREW
(4) Lower the vehicle.
19 N-m
(14 ft-lbs). CLAMP J9216-6

Fig. 15 Rear Propeller Shaft
(2) Tighten the U-joint strap bolts to; CENTER BEARING
• Dana Axle: 29 N-m (22 ft. lbs.) torque. Vehicles equipped with a two-piece rear propeller
• 9 1/4 Axle: 19 N-m (14 ft. lbs.) torque. shaft have a rubber insulated center bearing. The
(3) Remove support and lower the vehicle. bearing supports the shafts where they join together.
The two-piece propeller shaft uses two types of cen
TWO PIECE PROPELLER SHAFT—REAR ter bearings. Type 1 is used with the 9 1/4 axle. Type
The two piece shaft has a center bearing which 2 is used with the Dana axles. Both types are
supports the shafts where they are joined together mounted in the same location and service the same.
(Fig. 16).
REMOVAL
(1) Remove rear two-piece shaft. Refer to two-
-piece removal.
(2) Remove slip joint boot clamp and separate the
two shafts. The slip joints are master splined.
(3) Use hammer and punch to tap slinger away
from shaft to provide room for bearing splitter.
(4) Position Bearing Splitter Tool 1130 between
slinger and shaft.
CAUTION: Do not damage shaft spline during

removal of center bearing.
(5) Set shaft in press and press bearing off the

TYPE 2 TYPE 1
shaft.
J9416-2
INSTALLATION
Fig. 16 Center Bearing (1) Install new slinger on shaft and drive into posi
REMOVAL
tion with 2 1/2 in. ID pipe for type 1 center bearing.
For type 2 center bearing use 2 1/4 in. ID pipe to
(1) Shift the transmission/transfer case to their
install slinger.
Neutral positions. Raise and support vehicle.
(2) Install new center bearing on shaft with Bear
(2) Scribe alignment marks on the pinion yoke.
ing Installer Tool 6052. Drive on shaft with hammer
(3) Remove the universal joint strap bolts at the
until bearing is seated.
pinion shaft yoke.
DIFFERENTIAL AND DRIVELINE 3- I
mm
D I S A S S E M B L Y AND A S S E M B L Y (Continued)
(3) Clean shaft splines and apply a coat of multi-
-purpose grease.
(4) Align master splines and slide front and rear
shafts together. Reposition slip yoke boot and install
new clamp.
(5) Install two-piece shaft in vehicle. Refer to
installation two-piece shaft.
SINGLE CARDAN
REMOVAL
Single cardan universal joints are not serviceable.
If worn or leaking, they must be replaced as a unit.
(1) Remove the propeller shaft. Refer to Propeller
Shaft Replacement in this Group.
(2) Paint or score alignment marks on the
yokes and propeller shaft for installation refer
ence.
(3) Using a soft drift, tap the outside of the bear
ing assembly to loosen snap ring.
(4) Remove snap rings from both sides of yoke J9316-2V
(Fig. 17).
Fig. 18 Press Out Bearing
CAUTION: If the cross or bearing assembly are
cocked when being pressed, the bearing assembly
will score the walls of the yoke bore and ruin the
yoke.
J9316-19
Fig. 17 Remove Snap Ring BEARING
(5) Set the yoke in an arbor press or vise with a

large socket beneath it. Position the yoke with the
grease fitting pointing up (if equipped). Place a
smaller socket on the upper bearing assembly and
press it through to release the lower bearing assem
bly (Fig. 18).
(6) I f the bearing assembly will not pull out by J9316-24
hand after pressing, tap the base of the lug near it to
Fig. 19 Press Out Remaining Bearing
dislodge.
(7) To remove the opposite bearing, turn the yoke
over and straighten the cross in the open hole. Then
carefully press the end of the cross until the remain
ing bearing can be removed (Fig. 19).
3 - 10 DIFFERENTIAL AND DRIVELINE BR
D I S A S S E M B L Y A N D A S S E M B L Y {Continued)
ASSEMBLY (4) Press the bearing assembly into the cross hole
(1) Apply extreme pressure (EP) N.L.G.I. Grade 1 enough to install a snap ring. Install a snap ring.
or 2 grease to aid in installation. (5) Repeat steps 3 and 4 to install the opposite
(2) Position the cross in the yoke with its lube fit bearing assembly. I f the joint is stiff, strike the yoke
ting (if equipped) pointing up (Fig. 20). with a soft hammer to seat the needle bearings.
Install a snap ring.
CROSS
(6) Add grease to lube fitting (if equipped),
(7) Install the propeller shaft.
DOUBLE CARDAN (CV)
REMOVAL
Cardan universal joints are not serviceable. I f worn
or leaking, they must be replaced as a unit.
(1) Remove the propeller shaft. Refer to Propeller
Shaft Replacement in this Group.
(2) Paint or score alignment marks on the
yokes and propeller shaft for installation refer
ence.
(3) Remove all the bearing assembly snap rings
(Fig. 22).
J9316-22
Fig, 20 install Cross in Yoke

(3) Place a bearing assembly over the trunnion
and align i t with the cross hole (Fig. 21). Keep the
needle bearings upright in the bearing assembly. A
needle roller, lying at the bottom will prevent proper
assembly.
J9316-5
Fig. 22 Remove Snap Rings
Fig. 21 install Bearing On Trunnion

BR DIFFERENTIAL ANU UKIVCLHU.
D I S A S S E M B L Y AND A S S E M B L Y {Continued)
(4) Press the bearing assembly partially from the (6) Flip assembly and repeat steps 4 and 5 for
outboard side of the center yoke, enough to grasp by removing the opposite side bearing. This will then
vise jaws (Fig. 23). Be sure to remove grease fittings allow removal of the cross centering kit assembly and
that interfere with removal. spring (Fig. 25).
J9316-8
J9316-6
Fig. 25 Remove Centering Kit
Fig. 23 Press Out Bearing
(7) Press the remaining bearing assemblies out the
(5) Grasp the protruding bearing by vise jaws. Tap other cross as described above to complete the disas
the tube yoke with a mallet and drift to dislodge sembly.
from the yoke (Fig. 24).
INSTALLATION
During installation, ensure that the spiders
and yokes are aligned to the reference marks.
(1) Fit a cross into the tube yoke (Fig. 26).
J9316-7 J9316-9
Fig. 24 Remove Bearing From Yoke Fig. 26 install Cross In Yoke

_ . ..1L.1MHML ANU DRIVELINE ^ ^ • ^ • ^ BR
D I S A S S E M B L Y AND A S S E M B L Y {Continued)
• (2) Place a bearing assembly in a tube yoke hole (4) Flip the tube yoke and bearing assembly instal
and over a trunnion. Keep the needle bearings lation on the opposite trunnion. Install a snap ring
upright in the bearing assembly (Fig. 27). A needle (Fig. 29).
roller lying at the bottom will prevent proper assem
bly. Be sure to remove any lube fittings that may
interfere with removal.
(5) Fit the center yoke on the remaining two trun-

Fig. 27 Install Bearing Assembly n i o n s a n d p r e s s b e a r i n g a s s e m b l i e s i n p l a c e , b o t h
(3) Press the bearing assembly in place and install sides (Fig. 30). Install a snap ring,
a snap ring (Fig. 28).
Fig. 28 Press In Bearing Assembly

BR DIFFERENTIAL AND DRIVELINE 3 -13
D I S A S S E M B L Y AND A S S E M B L Y (Continue
(6) Install the centering kit assembly inside the
center yoke making sure the spring is i n place (Fig.
31).
Fig. 33 Press in Bearing Assembly

J9316-14
Fig. 31 instail Centering Kit

(7) Place two bearing assemblies on the remaining
cross (opposite sides). Fit the open trunnions into the
center yoke holes and the bearing assemblies into the
centering kit (Fig. 32).
J9316-17
Fig. 84 Seat Snap Rings In Groove

CLEANING AND INSPECTION
J9316-15
SINGLE AND DOUBLE CARDAN JOINT
Fig. 32 instaii Remaining Cross (1) Clean all the universal joint yoke bores with
(8) Press the remaining two bearing assemblies cleaning solvent and a wire brush.
into place and install snap rings (Fig. 33). (2) Inspect the yokes for distortion, cracks and
(9) Tap the snap rings to allow them to seat into worn bearing assembly bores.
the grooves (Fig. 34).
(10) Check for proper assembly. Flex the CV joint
beyond center, it should snap over-center in both
directions when correctly assembled (Fig. 35).
(11) Install the propeller shaft.
3 -14 DIFFERENTIAL AND DRIVELINE — — • — — BR
washers. Replace the original bolts with the appropriate

increased length bolts.
J9316-18
Fig. 35 Check Assembly

ADJUSTMENTS
ADJUSTMENT AT AXLE WITH LEAF SPRINGS J9316-25
Adjust the pinion shaft angle at the springs with
Fig. 37 Angle Adjustment at Center Bearing
tapered shims (Fig. 36). Install tapered shims between
the springs and axle pad to correct the angle. Refer to SPECIFICATIONS
Rear Suspension for additional information.
TORQUE
DESCRIPTION TORQUE
FRONT SHAFT
Bolts, flange yoke 88 N-m (65 ft. lbs.)
Bolts, axle yoke ...... .19 N-m (14 ft. lbs.)
REAR SHAFT AXLE YOKE BOLTS
9 1/4 Axle . . . . . . . . . . . . . . .19 N-m (14 ft. lbs.)
Dana Axle. . 30 N-m (22 ft. lbs.)
CENTER BEARING BRACKET
Frame Bolts .68 N-m (50 ft. lbs.)
Bearing Bolts .68 N-m (50 ft. lbs.)
SPECIAL TOOLS
PROPELLER SHAFT
Fig. 36 Adjustment at Leaf Springs—Typical
CENTER BEARING ADJUSTMENT—TWO PIECE
SHAFT
Drive away shudder is the vibration that occurs at first
acceleration from a stop. Shudder vibration usually peaks
at the engines highest torque output. Shudder is a symp
tom associated on vehicles using a two-piece prop shaft.
To decreased shudder lowering the center bearing in 1/8
inch increments. Use shim stock or fabricated plates (Fig.
37). Plate stock must be used to maintain compression of
the rubber insulator around the bearing. Do not use Inclinometer—7663
BR — DIFFERENTIAL AND DRIVELINE 3 -15
FRONT AXLE—MODEL 44/80
INDEX
page page
GENERAL INFORMATION FINAL ASSEMBLY 38

FRONT DRIVE AXLE 15 HUB BEARING AND AXLE SHAFT 26
GENERAL INFORMATION 15 INTERMEDIATE AXLE SHAFT . . . . . . . . . . 32
LUBRICANT SPECIFICATIONS 16 PINION GEAR 34
STANDARD DIFFERENTIAL OPERATION 16 PINION SHAFT SEAL REPLACEMENT . 28
VACUUM DISCONNECT 17 RING GEAR 34
DIAGNOSIS AND TESTING STEERING KNUCKLE 44 AXLE . . . . . . . . . 26
DIAGNOSIS INFORMATION 17 STEERING KNUCKLE 60 AXLE . . . . 26
DRIVELINE SNAP 18 VACUUM SHIFT MOTOR 24
FRONT DRIVE AXLE 19 ISASSEMBLY AND ASSEMBLY
GEAR AND BEARING NOISE 18 AXLE SHAFT—CARDAN U-JOINT . . . . . . . 38
LOW SPEED KNOCK 18 STANDARD DIFFERENTIAL 39
VACUUM DISCONNECT AXLE/SHIFT MOTOR LEANING AND INSPECTION
DIAGNOSIS 21 AXLE COMPONENTS 39
VIBRATION 18 ADJUSTMENTS
SERVICE PROCEDURES DIFFERENTIAL BEARING PRELOAD AND
LUBRICANT CHANGE 24 GEAR LASH 42
REMOVAL AND INSTALLATION PINION GEAR DEPTH . . . . . . . . . . . . . . . . . . . . 40
AXLE SHAFT OIL SEAL 32 SPECIFICATIONS
BALL STUDS 44 AXLE 27 FRONT AXLE . 45
BALL STUDS 60 AXLE 27 TORQUE . 45
DIFFERENTIAL SIDE BEARINGS 32 SPECIAL TOOLS
DIFFERENTIAL 30 FRONT AXLE 46
DRIVE AXLE ASSEMBLY REPLACEMENT 25
GENERAL INFORMATION The stamped steel cover provides a means for

inspection and servicing the differential.
GENERAL INFORMATION The Model 44/60 axle has the assembly part num
The housing for Model 44/60 front axles consists of ber and gear ratio listed on a tag. The tag is attached
an iron center casting with tubes on each side. The to the housing cover. Build date identification codes
tubes are pressed into and welded to the differential are stamped on the axle shaft tube cover side.
housing. The differential case is a one-piece design. The dif
The integral type housing, hypoid gear design has ferential pinion mate shaft is retained with a roll
the centerline of the pinion set below the centerline pin. Differential bearing preload and ring gear back
of the ring gear. lash is adjusted by the use of shims. The shims are
The axle has a vent used to relieve internal pres located between the differential bearing cones and
sure caused by lubricant vaporization and internal case. Pinion bearing preload is set and maintained by
the use of a collapsible spacer.
expansion.
The axles are equipped with semi-floating axle
shafts, meaning that loads are supported by the hub FRONT DRIVE AXLE
bearings. The axle shafts are retained by nuts at the The integral type housing, has the centerline of the
hub bearings. The hub bearings are bolted to the pinion set below the centerline of the ring gear.
steering knuckle at the outboard end of the axle tube The axles are equipped with optional A.B.S. brake
yoke. The hub bearings are serviced as an assembly. system. The A.B.S. tone rings are pressed onto the
The axles are equipped with ABS brake sensors. axle shaft near the hub and knuckle. For additional
The sensors are attached to the knuckle assemblies information on the A.B.S. system refer to Group 5,
and tone rings are pressed on the axle shaft. Use Brakes.
care when removing axle shafts as NOT to dam The Dana 44 and 60 axle has the assembly part
age the tone wheel or the sensor. number and gear ratio listed on a tag. The tag is
3 - 16 DIFFERENTIAL AND DRIVELINE
mm
attached to the housing cover (Fig, 1) or (Fig. 2). Refer to Group 0, Lubrication and Maintenance for
Build date identification codes are stamped on the additional information.
axle shaft tube cover side.
CAUTION: If axle is submerged in water, the lubri
DIFFERENTIAL cant must be replaced immediately to avoid con
COVER tamination.
FILL PLUG
STANDARD DIFFERENTIAL OPERATION

The differential gear system divides the torque
between the axle shafts. I t allows the axle shafts to
rotate at different speeds when turning corners.
Each differential side gear is splined to' an axle
shaft. The pinion gears are mounted on a pinion
mate shaft and are free to rotate on the shaft. The
pinion gear is fitted in a bore in the differential case
and is positioned at a right angle to the axle shafts.
In operation, power flow occurs as follows:
• Pinion gear rotates the ring gear
• Ring gear (bolted to the differential case) rotates
the case
• Differential pinion gears (mounted on the pinion
mate shaft in the case) rotate the side gears
IDENTIFICATION
TAG
• Side gears (splined to the axle shafts) rotate the
J9202-23
shafts
Fig. 1 Model 44 Differential Cower
During straight-ahead driving, the differential pin
ion gears do not rotate on the pinion mate shaft. This
DIFFERENTIAL
FILL PLUG occurs because input torque applied to the gears is
COVER
divided and distributed equally between the two side
gears. As a result, the pinion gears revolve with the
pinion mate shaft but do not rotate around i t (Fig. 3).
I N STRAIGHT A H E A D DRIVING
EACH WHEEL ROTATES AT 100%
OF CASE SPEED
MODEL
NUMBER
J9202-97 P I N I O N GEARS ROTATE

WITH CASE J9303-13
Fig. 2 Model 60 Differential Cower
Fig. 8 Differential Operation—Straight Ahead Driving
LUBRICANT SPECIFICATIONS
Thermal Stable Multi-Purpose Gear Lubricant is
When turning corners, the outside wheel must
used for Model 44/60 axles. The lubricant should
travel a greater distance than the inside wheel in
have API GL 5 quality specifications. Mopar, Ther
order to complete a turn. This difference must be
mal Stable Multi-Purpose Gear Lubricant conforms
compensated for in order to prevent the wheels from
to these specifications. scuffing and skidding through the turn. To accom
• The factory fill for the Model 44/60 axle is SAE plish this the differential allows the axle shafts to
80W-90 gear lubricant turn at unequal speeds (Fig. 4). In this instance, the
BR DIFFERENTIAL AND DRIVELINE 3 - 17
G E N E R A L I N F O R M A T I O N fContinued)
input torque applied to the pinion gears is not P i ^ Q U Q S I S Mm TESTING
divided equally. The pinion gears now rotate around
the pinion mate shaft in opposite directions. This DIAGNOSES INFORMATION
allows the side gear and axle shaft attached to the Axle bearing problem conditions are usually caused
outside wheel to rotate at a faster speed. by:
• Insufficient or incorrect lubricant
j AXLE f j • Foreign matter/water contamination
OUTER WHEEL 1 0 0 % DIFFERENTIAL INNER WHEEL • Incorrect bearing preload torque adjustment
1 1 0 % CASE SPEED CASE SPEED 9 0 % CASE SPEED
• Incorrect backlash (to tight)
When serviced, the bearings must be cleaned thor
oughly. They should be dried with lint-free shop tow
els. Never dry bearings with compressed air.
This will overheat them and brinell the bearing
surfaces. This will result in noisy operation
after repair.
Axle gear problem conditions are usually the result
of:
• Insufficient lubrication
PINION G E A R S ROTATE • Incorrect or contaminated lubricant
O N PINION SHAFT J9303-14 • Overloading (excessive engine torque)
» Exceeding vehicle weight capacity
Fig. 4 Differential Operation—On Turns • Incorrect clearance or backlash adjustment
VACUUM DISCONNECT Insufficient lubrication is usually the result of a
housing cover leak. I t can also be from worn axle
VACUUM CONTROL SYSTEM shaft or pinion gear seals. Check for cracks or porous
The disconnect axle control system consists of; areas in the housing or tubes.
• Shift motor Using the * wrong lubricant will cause overheating
• Indicator switch and gear failure. Gear tooth cracking and bearing
• Vacuum switch spalling are indicators of this.
• Vacuum harness (Fig. 5) Axle component breakage is most often the result
of:
CHECK • Severe overloading
VALVE
• Insufficient lubricant
• Incorrect lubricant
• Improperly tightened components
Common causes of overloading is from full throttle
acceleration. Overloading happens when towing
heavier than recommended loads. Component break
age can occur when the wheels are spun excessively.
Insufficient or incorrect lubricants contribute to
breakage through overheating. Loose differential
components can also cause breakage.
Incorrect bearing preload or gear backlash will not
result in component breakage. This will cause accel
erated wear and contribute to early failure. Mis-ad
justment will produce noise. I f a mis-adjustment
condition is not corrected, component failure can
result.
Excessive bearing preload may not be noisy. This
condition will cause high temperature which can
SHIFT
result in bearing failure.
MOTOR . J9202-55
Fig. 5 Vacuum Control System

Refer to Group 21 Transmissions for addi
tional information.
DIAGNOSIS AND T E S T I N G (Continued)
GEAR AND BEARING NOISE LOW SPEED KNOCK

Low speed knock is generally caused by a worn
GEAR NOISE U-joint or by worn side-gear thrust washers. A worn
Axle gear noise can be caused by insufficient lubri pinion gear shaft bore will also cause low speed
cant. Incorrect backlash, tooth contact, or worn/dam knock.
aged gears can cause noise.
Gear noise usually happens • at a specific speed VIBRATION
range. The range is 30 to 40 mph, or above 50 mph. Vibration at the rear of the vehicle is usually
The noise can also occur during a specific type of caused by:
driving condition. These conditions are acceleration, • Damaged drive shaft
deceleration, coast, or constant load. • Missing drive shaft balance weight
When road testing, accelerate the vehicle to the • Worn, out-of-balance wheels
speed range where the noise is the greatest. Shift • Loose wheel lug nuts
out-of-gear and coast through the peak-noise range. • Worn U-joint
I f the noise stops or changes greatly, check for insuf • Loose spring U-bolts
ficient lubricant. Incorrect ring gear backlash, or • Loose/broken springs
gear damage can cause noise changes. • Damaged axle shaft bearings
Differential side and pinion gears can be checked • Loose pinion gear nut
by turning the vehicle. They usually do not cause • Excessive pinion yoke run out
noise in straight-ahead driving. The side gears are • Bent axle shaft
loaded during vehicle turns. I f noise does occur dur Check for loose or damaged front-end components
ing vehicle turns, the side or pinion gears could be or engine/transmission mounts. These components
worn or damaged. A worn pinion gear mate shaft can can contribute to what appears to be a rear-end
also cause a snapping or a knocking noise. vibration. Do not overlook engine accessories, brack
ets and drive belts.
BEARING NOISE All driveline components should be examined
The axle shaft, differential and pinion gear bear before starting any repair.
ings can all produce noise when worn or damaged. Refer to Group 22, Tires And Wheels for additional
Bearing noise can be either a whining, or a growling information involving vibration diagnosis.
sound.
Pinion gear bearings have a constant-pitch noise. DRIVELINE SNAP
This noise changes only with vehicle speed. Pinion A snap or clunk noise when the vehicle is shifted
bearing noise will be higher because it rotates at a into gear (or the clutch engaged), can be caused by:
faster rate. Drive the vehicle and load the differen • High engine idle speed
tial. If bearing noise occurs the pinion rear bearing is • Loose engine/transmission/transfer case mounts
the source of the noise. I f the bearing noise is heard • Worn U-joints
during a coast, front bearing is the source. ® Loose spring mounts
Worn, damaged differential bearings usually pro • Loose pinion gear nut and yoke
duce a low pitch noise. Differential bearing noise is • Excessive ring gear backlash
similar to pinion bearing. The pitch of differential • Excessive side gear/case clearance
bearing noise is also constant and varies only with The source of a snap or a clunk noise can be deter
vehicle speed. mined with the assistance of a helper. Raise the vehi
Axle shaft bearings produce noise and vibration cle on a hoist with the wheels free to rotate. Instruct
when worn or damaged. The noise generally changes the helper to shift the transmission into gear. Listen
when the bearings are loaded. Road test the vehicle. for the noise, a mechanics stethoscope is helpful in
Turn the vehicle sharply to the left and to the right. isolating the source of a noise.
This will load the bearings and change the noise
level. Where axle bearing damage is slight, the noise
is usually not noticeable at speeds above 30 mph.
BR — _____—_____ DIFFERENTIAL AND DRIVELINE 3 - 19
D I A G N O S I S AND T E S T I N G (Continued)
FRONT DRIVE AXLE DIAGNOSIS
WHEEL NOISE 1. Wheel loose. 1. Tighten loose nuts.

2. Faulty, brinelled wheel bearing. 2. Faulty or brinelled bearings must be replaced.
AXLE SHAFT N O I S E 1. Misaligned axle shaft tube. 1. Inspect axle shaft tube alignment. Correct as necessary.
2. Bent or sprung axle shaft. 2. Replace bent or sprung axle shaft.
3. End play in drive pinion 3. Refer to Drive Pinion Bearing Pre-Load Adjustment.
bearings.
4 . Excessive gear backlash 4 . Check adjustment of ring gear backlash and pinion gear.
between ring gear and pinion Correct as necessary.
gear.
5. Improper adjustment of drive 5. Adjust drive pinion shaft bearings.
pinion gear shaft bearings.
6. Loose drive pinion gearshaft 6. Tighten drive pinion gearshaft yoke nut with' specified torque.
yoke nut.
7. Improper wheel bearing 7. Readjust as necessary.
adjustment.
8. Scuffed gear tooth contact 8. If necessary, replace scuffed gears.
surfaces.
AXLE SHAFT BROKE 1. Misaligned axle shaft tube. 1. Replace broken axle shaft after correcting axle shaft tube
alignment.
2. Vehicle overloaded. 2. Replace broken axle shaft. Avoid excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken axle shaft after inspecting for other possible
causes. Avoid erratic use of clutch.
4. Grabbing clutch. 4. Replace broken axle shaft. Inspect clutch and make necessary
repairs or adjustments.
DIFFERENTIAL CASE 1. Improper adjustment of 1. Replace cracked case; examine gears and bearings for possible
CRACKED differential bearings. damage. At reassembly, adjust differential bearings properly.
2. Replace cracked case; examine gears and bearings for possible \
2. Excessive ring gear backlash. damage. At reassembly, adjust ring gear backlash properly.
3. Replace cracked case; examine gears and bearings for possible
3. Vehicle overloaded. damage. Avoid excessive weight on vehicle.
4. Replace cracked case. After inspecting for other possible
4. Erratic clutch operation. causes, examine gears and bearings for possible damage.
Avoid erratic use of clutch.
DIFFERENTIAL G E A R S 1. Insufficient lubrication. 1. Replace scored gears. Scoring marks on the drive face of gear
SCORED teeth or in the bore are caused by instantaneous fusing of the
mating surfaces. Scored gears should be replaced. Fill rear
differential housing to required capacity with proper lubricant.
Refer to Specifications.
2. Improper grade of lubricant. 2. Replace scored gears. Inspect all gears and bearings for
possible damage. Clean and refill differential housing to
required capacity with proper lubricant.
3. Excessive spinning of one 3. Replace scored gears. Inspect all gears, pinion bores and shaft
wheel/tire. for damage. Service as necessary.
LOSS O F LUBRICANT 1. Lubricant level too high. 1. Drain excess lubricant by removing fill plug and allow lubricant
to level at lower edge of fill plug hole.
J9503-3
3 - 20 DIFFERENTIAL AND DRIVELINE _ _ _ _ _ BR
CONTINUED
CONDITION P O S S I B L E CAUSES CORRECTION
LOSS OF LUBRICANT 2. Worn axle shaft seals. 2. Replace worn seals.

3. Cracked differential housing. 3. Repair or replace housing as necessary.
4. Worn drive pinion gear shaft 4. Replace worn drive pinion gear shaft seal.
seal.
5. Scored and worn yoke. 5. Replace worn or scored yoke and seal.
6. Axle cover not properly sealed. 6. Remove cover and clean flange and reseal.
AXLE OVERHEATING 1. Lubricant level too low. 1. Refill differential housing.

2. Incorrect grade of lubricant. 2. Drain, flush and refill with correct amount of the correct
lubricant.
3. Bearings adjusted too tight. 3. Readjust bearings.
4. Excessive gear wear. 4. Inspect gears for excessive wear or scoring. Replace as
necessary.
5. Insufficient ring gear backlash. 5. Readjust ring gear backlash and inspect gears for possible
scoring. j
GEAR TEETH BROKE 1. Overloading. 1. Replace gears. Examine other gears and bearings for possible
(RING GEAR A N D PINION) damage.
2. Erratic clutch operation. 2. Replace gears and examine the remaining parts for possible ;.
damage. Avoid erratic clutch operation. j
3. Ice-spotted pavements. 3. Replace gears. Examine the remaining parts for possible
damage. Replace parts as required.
4. Improper adjustments. 4. Replace gears. Examine other parts for possible damage.
Ensure ring gear backlash is correct.
AXLE NOISE 1. Insufficient lubricant. 1. Refill axle with correct amount of the proper lubricant.
Also inspect for leaks and correct as necessary.
2. Improper ring gear and drive 2. Check ring gear and pinion gear teeth contact pattern.
pinion gear adjustment.
3. Unmatched ring gear and drive 3. Remove unmatched ring gear and drive pinion gear.
pinion gear. Replace with matched gear and drive pinion gear set.
4. Worn teeth on ring gear or 4. Check teeth on ring gear and drive pinion gear for correct
drive pinion gear. contact. If necessary, replace with new matched set.
5. Loose drive pinion gear shaft 5. Adjust drive pinion gearshaft bearing preload torque.
bearings.
6. Loose differential bearings. 6. Adjust differential bearing preload torque.
7. Misaligned or sprung ring gear. 7. Measure ring gear runout.
8. Loose differential bearing cap 8. Tighten with specified torque
bolts
J9503-4
DIFFERENTIAL AND DRlfELlNE 3 - 21
VACUUM DISCONNECT AXLE/SHIFT MOTOR CHECK

VALVE
DIAGNOSIS
VACUUM CONTROL SYSTEM

The disconnect axle control system consists of;
• Shift motor
• Indicator switch
• Vacuum switch
• Vacuum harness (Fig. 6)
Refer to Group 21 Transmissions for addi
tional information.
SHIFT
MOTOR J9202-55
Fig. 6 Vacuum Control System

DISCONNECT AXLE/SHIFT MOTOR DIAGNOSIS
TWO-WHEEL DRIVE OPERATION DIAGNOSIS
FOUR-WHEEL DRIVE
INDICATOR LIGHT WILL
NOT G O OUT W H E N
TRANSFER CASE SELECTOR
IS MOVED FROM 4H TO
2H POSITION.
YES '
START ENGINE DEPRESS BRAKE

INSPECT INDICATOR PEDAL. PLACE TRANSFER
KAISE VEHICLE S O ALL SWITCH AND W I R I N G O N CASE SELECTOR IN 2H POSITION
FOUR WHEELS ARE SHIFT MOTOR H O U S I N G AND TRANSMISSION IN
FREE TO ROTATE. FOR DAMAGE AND DRIVE (AUTOMATIC) OR FIRST
SHORT-CIRCUIT. GEAR (MANUAL). EASE OFF FROM
REPAIR AS NECESSARY. BRAKE AND LET WHEELS ROTATE
SLOWLY.
FRONT DRIVE FRONT DRIVE

SHAFT DOES SHAFT ROTATES.
NOT ROTATE.
INSPECT TRANSFER
FOUR-WHEEL DRIVE CASE LINKAGE.
INDICATOR LIGHT
REMAINS O N .
CHECK TRANSFER
CASE. REPAIR
PLACE TRANSMISSION AS NECESSARY.
IN NEUTRAL. TEST FOR VACUUM
IN VACUUM HOSE
THAT CONNECTS TO
INBOARD SHIFT
DICONNECT THE MOTOR PORT.
SHIFT MOTOR VACUUM (VACUUM SHOULD BE
HOSES. BETWEEN 10-20 IN. HG.)
1
VACUUM OK
N O VACUUM
OR LOW VACUUM.
z x z
STOP ENGINE
INSPECT INTAKE MANIFOLD

VACUUM SUPPLY HOSE C O N N E C T I O N ,
±
CONNECT A VACUUM
TRANSFER CASE VACUUM SWITCH
C O N N E C T I O N , VACUUM RESERVOIR, PUMP TO THE INBOARD
AND SHIFT SYSTEM VACUUM HOSES SHIFT MOTOR PORT.
FOR PROPER C O N N E C T I O N , RESTRICTION, APPLY 15 IN. H G
AIR LEAKS, AND DAMAGE. REPAIR OR REPLACE VACUUM AND ROTATE
AS NECESSARY. RIGHT WHEEL.
FRONT AXLE FRONT AXLE

DISCONNECTS. D O E S NOT
DISCONNECT.
INSPECT VACUUM
HOSES FOR AIR LEAKS, KINKS, ETC.
REPAIR AS NECESSARY. REMOVE SHIFT MOTOR
H O U S I N G COVER. C O N N E C T
VACUUM PUMP TO
SHIFT MOTOR PORT. FRONT AXLE
REPLACE SHIFT MOTOR WILL NOT DISCONNECT.
IF ARMATURE D O E S
NOT MOVE IN A N D O U T
FREELY.
REMOVE SHIFT MOTOR H O U S I N G
COVER. INSPECT SHIFT FORK,
COLLAR, AND AXLE SHAFTS.
REPAIR OR REPLACE AS
J9G02-95 NECESSARY.
BR DIFFERENTIAL AND DRIWEL1NE '3 - 23
DISCONNECT AXLE/SHIFT MOTOR DIAGNOSIS (CONT'D)
FOUR-WHEEL DRIVE OPERATION DIAGNOSIS
FOUR-WHEEL DRIVE INDICATOR

LIGHT DOES NOT LIGHT WHEN
TRANSFER CASE SELECTOR IN
4H OR4L POSITION.
RAISE VEHICLE SO ALL FOUR

WHEELS ARE FREE TO ROTATE.
START ENGINE, DEPRESS BRAKE PEDAL.

PLACE TRANSFER CASE SELECTOR IN 4H
POSITION AND TRANSMISSION LEVER IN
DRIVE (AUTOMATIC) OR IN FIRST GEAR
(MANUAL) TO CONFIRM TRANSFER CASE
ENGAGEMENT IN 4H. LET WHEELS
ROTATE SLOWLY.
FRONT DRIVE FRONT DRIVE

SHAFT DOES SHAFT TURNS.
NOT ROTATE.
INSPECT TRANSFER FRONT AXLE RECOMMENDATION:

CHECK VACUUM PLACE TRANSMISSION FRONT AXLE
CASE LINKAGE. CONNECTS. LEVER IN NEUTRAL DOES NOT
SHIFT SYSTEM
FOR PROPER POSITION. CONNECT.
OPERATION.
CHECK TRANSFER FOUR-WHEEL DRIVE
CASE. REPAIR AS INDICATOR LIGHT
NECESSARY. DOES NOT LIGHT. REMOVE VACUUM HOSES
FROM AXLE SHIFT
MOTOR PORTS.
INSPECT FWD INDICATOR

SWITCH, WIRING, AND START ENGINE. TEST FOR VACUUM
LAMP FOR DAMAGE. AT HOSE REMOVED FROM OUT
REPAIR AS NECESSARY. BOARD PORT O N SHIFT MOTOR,
SHOULD BE BETWEEN 10-20 IN HG.
NO VACUUM STOP ENGINE VACUUM OK

OR LOW VACUUM. K
CONNECT A VACUUM PUMP
INSPECT INTAKE MANIFOLD TO THE OUTBOARD
VACUUM SUPPLY HOSE CONNECTION, SHIFT MOTOR PORT.
TRANSFER CASE VACUUM SWITCH APPLY 15 INCHES HG. VACUUM
CONNECTION, VACUUM RESERVOIR, AND SHIFT AND ROTATE LEFT WHEEL.
SYSTEM VACUUM HOSES FOR PROPER CONNECTION,
RESTRICTION, LEAKS, AND DAMAGE.
REPAIR OR REPLACE AS NECESSARY.
FRONT AXLE FRONT AXLE

NO VACUUM CONNECTED. DOES NOT
CONNECT.
CHECK TRANSFER CASE

VACUUM SWITCH. REPLACE INSPECT VACUUM HOSES
OR REPAIR IF SWITCH FOR LEAKS, KINKS, ETC. REMOVE SHIFT MOTOR
PLUNGER IS DIFFICULT TO REPAIR AS NECESSARY. HOUSING COVER. CONNECT
MOVE OR BINDS. VACUUM PUMP TO
SHIFT MOTOR PORT.
REPLACE SHIFT MOTOR
IF ARMATURE DOES
NOT MOVE IN AND OUT
FREELY.
REMOVE SHIFT MOTOR HOUSING _ _ _ i: .

COVER. INSPECT SHIFT FORK,
FRONT AXLE
COLLAR, AND AXLE SHAFTS.
WILL NOT CONNECT.
REPAIR OR REPLACE AS
NECESSARY.
J9002-96
SERVICE PROCEDURES REMOVAL AND INSTALLATION
LUBRICANT CHANGE VACUUM SHIFT MOTOR

The gear lubricant will drain quicker i f the vehicle
has been recently driven. R E M O V E AND DISASSEMBLE
(1) Raise and support the vehicle. (1) Disconnect the vacuum and wiring connector
(2) Remove the lubricant fill hole plug from the from the shift housing.
differential housing cover. (2) Remove indicator switch.
(3) Remove the differential housing cover and (3) Remove the shift motor housing cover, gasket
drain the lubricant from the housing. and shield from the housing (Fig. 8).
(4) Clean the housing cavity with a flushing oil,
light engine oil or lint free cloth. Do not use water, DISCONNECT VACUUM
INDICATOR LAMP SHIFT
steam, kerosene or gasoline for cleaning. HOUSING
SWITCH MOTOR
(5) Remove the sealant from the housing and cover /
surfaces. Use solvent to clean the mating surfaces.
(6) Apply a bead of Mopar, Silicone Rubber Sealant INTERMEDIATE
AXLE SHAFT
to the housing cover (Fig. 7). Allow the sealant to
cure for a few minutes.
SEALING CONTOUR OF BEAD
SURFACE
BEARING
SHIFT FORK SHIFT SEAL

COLLAR
J9402-63
Fig. 8 Shift Motor Housing

(4) Remove the E-clips from the shift motor hous
ing and shaft. Remove shift motor and shift fork from
the housing (Fig. 9).
INDICATOR
SWITCH
BEAD
THICKNESS
6.35mm (1/4") J9302-30
Fig. 7 Typicai Housing Cover With Sealant

Install the housing cover within 5 minutes
after applying the sealant. If not installed the VACUUM
sealant must be removed and another bead PORTS
applied.
J9202-54
(7) Install the cover and any identification tag.
Tighten the cover bolts in a criss-cross pattern to;
Fig. 9 Shift Motor Components
• Model 44: 41 N-m (30 ft. lbs.) torque.
• Model 60: 47 N-m (35 ft. lbs.) torque. (5) Remove the O-ring seal from the shift motor
(8) Refill differential with the specified quantity of shaft.
Mopar, Hypoid Gear Lubricant. (6) Clean and inspect all components. I f any com
ponent is excessively worn or damaged, it should be
CAUTION: Overfilling the differential can result in replaced.
lubricant foaming and overheating.
(9) Install the fill hole plug and lower the vehicle.
R E M O V A L AND INSTALLATION (Continued)
ASSEMBLY AMD INSTALL important to have the springs supporting the weight
(1) Install a new O-ring seal on the shift motor of the vehicle when the fasteners are tightened. If
shaft. springs are not at their normal ride position, vehicle
(2) Insert the shift motor shaft through the hole in ride comfort could be affected and premature bush
the housing and shift fork. The shift fork offset ing wear may occur. Rubber bushings must never
should be toward the differential. be lubricated.
(3) Install the E-clips on the shift motor shaft and
housing. (1) Install the springs, retainer clip and bolts.
(4) Install the shift motor housing gasket and (2) Support the axle on a hydraulic jack under the
cover. Ensure the shift fork is correctly guided differential. Position the axle under the vehicle.
into the shift collar groove. (3) Raise the axle with a floor jack and align it
(5) Install the shift motor housing shield and with the spring pads.
attaching bolts. Tighten the bolts to 11 N-m (96 in. (4) Position the upper and lower suspension arm
lbs.) torque. at the axle bracket. Install bolts, nuts and align cams
(6) Add 148 ml (5 ounces) of API grade GL 5 to reference marks. Do not tighten at this time.
hypoid gear lubricant to the shift motor housing. Add (5) Connect the track bar to the axle bracket and
lubricant through indicator switch mounting hole. install the bolt. Do not tighten at this time.
(7) Install indicator switch, electrical connector It is important that the springs support the
and vacuum harness. weight of the vehicle when the track bar is con
nected. If the springs are not at normal ride
DRIVE AXLE ASSEMBLY REPLACEMENT height, the vehicle ride comfort could be
affected.
REMOVAL (6) Install the shock absorber and tighten bolts to
(1) Raise vehicle and position support stands 121 N-m (89 ft. lbs.) torque.
under the frame rails behind the lower suspension (7) Install the stabilizer bar link to the axle
arm brackets. bracket. Tighten the nut to 37 N-m (27 ft. lbs.)
(2) Remove the front wheels assemblies. torque.
(3) Remove the brake components and ABS brake (8) Install the drag link and tie rod to the steering
sensor (if equipped). Refer to Group 5, Brakes. knuckles and tighten the nuts to 88 N-m (65 ft. lbs.)
(4) On 4WD vehicles, disconnect the axle vent torque.
hose. Disconnect vacuum hose and electrical connec (9) Install the brake components and ABS brake
tor at disconnect housing. sensor (if equipped). Refer to Group 5, Brakes.
(5) On 4WD vehicles, mark the drive shaft yoke, (10) On 4WD vehicles, connect the vent hose to the
axle pinion yoke and transfer case flange for align tube fitting. Connect vacuum hose and electrical con
ment reference. Disconnect the drive shaft from the nector to disconnect housing.
axle and transfer case. (11) On 4WD vehicles, align the reference marks
(6) Disconnect the stabilizer bar link at the axle and connect the drive shaft to the axle yoke and
bracket. transfer case flange. Tighten the U-joint clamp bolts
(7) Disconnect the shock absorbers from axle to 19 N-m (14 ft. lbs.) torque. Tighten flange bolts to
bracket. 88 N-m (65 ft. lbs.) torque.
(8) Disconnect the track bar from the axle bracket. (12) Check differential lubricant and add i f neces
(9) Disconnect the tie rod and drag link from the sary.
steering knuckle. (13) Install the wheel and tire assemblies.
(10) Support the axle with a hydraulic jack under (14) Remove the supports and lower the vehicle.
the differential. (15) Tighten the upper suspension arm nuts at
(11) Disconnect the upper and lower suspension axle to 121 N-m (89 ft. lbs.) torque. Tighten the
arms from the axle bracket. Mark cams for instal upper suspension arm nuts at frame to 84 N-m (62 ft.
lation reference. lbs.) torque.
(12) Lower the jack enough to remove the axle. (16) Tighten the lower suspension arm nuts at
The coil springs will drop with the axle. axle to 84 N-m (62 ft. lbs.) torque. Tighten the lower
(13) Remove the coil springs from the axle bracket. suspension arm nuts at frame to 119 N-m (88 ft. lbs.)
torque.
INSTALLATION (17) Tighten the track bar bolt at the axle bracket
to 176 N-m (130 ft. lbs.) torque.
CAUTION: Suspension components with rubber (18) Check the front wheel alignment.
bushings should be tightened with the weight of the
vehicle on the suspension, at normal height. It is
HUB BEARING AND AXLE SHAFT (2) Remove tie-rod or drag link end from the steer
ing knuckle arm. Remove the ABS sensor wire and
REMOVAL bracket from knuckle.
(1) Raise and support the vehicle. (3) Remove the cotter pin from the upper ball stud
(2) Remove the wheel and tire assembly. nut. Remove the upper and lower ball stud nuts.
(3) Remove the brake components from the axle, (4) Strike the steering knuckle with a brass ham
refer to Group 5, Brakes. mer to loosen. Remove knuckle from axle tube yokes.
(4) Remove the cotter pin and axle hub nut.
(5) Remove the hub to knuckle bolts (Fig. 10). KNUCKLE INSTALLATION
Remove the hub bearing from the steering knuckle (1) Position the steering knuckle on the ball studs.
and axle shaft. (2) Install and tighten lower ball stud nut to 108
N-m (80 ft. lbs.) torque. Advance nut to next slot to
line up hole and install new cotter pin.
(3) Install and tighten upper ball stud nut to 101
N-m (75 ft. lbs.) torque. Advance nut to next slot to
line up hole and install new cotter pin.
(4) Install the Hub Bearing and Axle Shaft. Refer
to the installation procedure.
(5) Install tie-rod or drag link end onto the steer
ing knuckle arm. Install the ABS sensor wire and
bracket to the knuckle, refer to Group 5, Brakes for
proper set-up.
STEERING KNUCKLE 60 AXLE
K N U C K L E REMOVAL
(1) Remove hub bearing and axle shaft. Refer to
the Removal procedures in this Group.
Fig. 10 Hub and Knuckle (2) Remove tie-rod or drag link end from the
(6) Remove the brake dust shield. steering knuckle arm. Remove the ABS sensor wire
(7) Remove the axle shaft from the housing. and bracket from knuckle.
Avoid damaging the axle shaft oil seal. (3) Remove the cotter pin from the upper ball stud
nut. Remove the upper and lower ball stud nuts.
INSTALLATION (4) Strike the steering knuckle with a brass ham
(1) Clean the axle shaft and apply a thin film of mer to loosen. Remove knuckle from axle tube yokes.
Mopar Wheel Bearing Grease to the shaft splines,
seal contact surface, hub bore. Install the axle shaft KNUCKLE INSTALLATION
into the housing and differential side gears. Avoid (1) Position the steering knuckle on the ball studs.
damaging the axle shaft oil seals in the differential. (2) Install and tighten lower ball stud nut to 47
(2) Install dust shield and hub bearing on knuckle. N-m (35 ft. lbs.) torque. Do not install cotter pin
(3) Install the hub bearing to knuckle bolts and at this time.
tighten to 170 N-m (125 ft. lbs.) torque. (3) Install and tighten upper ball stud nut to 94
(4) Install the axle washer and nut, tighten nut to N-m (70 ft. lbs.) torque. Advance nut to next slot to
237 N-m (175 ft. lbs.) torque. Align nut to next cotter line up hole and install new cotter pin. .
pin hole and install new cotter pin. (4) Retorque lower ball stud nut to 190 - 217 N-m
(5) Install the brake components, refer to Group 5, (140 - 160 ft. lbs.) torque. Advance nut to next slot to
Brakes. line up hole and install new cotter pin.
(6) Install the wheel and tire assembly. (5) Install the Hub Bearing and Axle Shaft. Refer
(7) Remove support and lower the vehicle. to the installation procedure.
(6) Install tie-rod or drag link end onto the steer
STEERING KNUCKLE 44 AXLE ing knuckle arm. Install the ABS sensor wire and
bracket to the knuckle, refer to Group 5, Brakes for
KNUCKLE REMOVAL proper set-up.
(1) Remove hub bearing and axle shaft. Refer to
the Removal procedures in this Group.
BALL STUDS 44 AXLE
UPPER BALL STUD REPLACEMENT

(1) Position tools as shown to remove ball stud
(Fig. 11).
J9402-48
Fig. 12 Upper Ball Stud Install
J9402-49
Fig. 11 Upper Ball Stud Remove

(2) Position tools as shown to install ball stud (Fig.
12).
L O W E R B A L L STUD REPLACEMENT
(Fig. 13).
14).
BALL STUDS 60 AXLE
UPPER BALL STUD REPLACEMENT

(Fig. 15).
16).
SPECIAL TOOL
C-4212F
J9402-51
Fig. 13 Lower Ball Stud Remove
3 - 28 DIFFERENTIAL AND DRIVELINE ^ — ^ ^ — BR
Fig. 17 Lower Ball Stud Remove

KNUCKLE
18).
PINION SHAFT SEAL REPLACEMENT

Jf402-38
REMOVAL
Fig. 15 Upper Ball Stud Remove (1) Raise and support the vehicle.
(2) Remove wheel and tire assemblies.
LOWER BALL STUD REPLACEMENT
(3) Mark the drive shaft yoke and pinion yoke for
installation alignment reference.
(Fig. 17).
KNUCKLE. (9) Use Remover 7794A and slide hammer to

remove the pinion gear seal (Fig. 20).
SPECIAL TOOL
7794A
SPECIAL TOOL
6759
SLIDE HAMMER
SPECIAL TOOL PINION SEAL

6760
J9402-59X
Fig. 20 Seal Removal

SPECIAL TOOL
C-4212F J9402-41
INSTALLATION
(1) Apply a light coating of gear lubricant on the
Fig. 18 Lower Bali Stud Install lip of pinion seal. Install seal with Installer D-163
and Handle C-4171 (Fig. 21).
(4) Remove the drive shaft from the yoke.
(5) Rotate the pinion gear three or four times.
Make sure brakes are not dragging during this
procedure. HANDLE
(6) Measure the amount of torque (in Newton-me

ters or inch-pounds) necessary to rotate the pinion
gear with a torque wrench. Note the torque for
installation reference. It must be known to prop
erly adjust the pinion gear bearing preload
torque after seal installation.
(7) Remove the pinion yoke nut and washer. Use
Remover C-452 and Wrench C-3281 to remove the
pinion yoke (Fig. 19).
(8) Mark the positions of the yoke and pinion gear
for installation alignment reference.
SPECIAL TOOL
C-3281 INSTALLER
J9502-1
Fig. 21 Pinion Seal Installation

(2) Align the installation reference marks and
install yoke on the pinion gear with Installer
W-162D.
(3) Install a new nut on the pinion gear. Tighten
the nut only enough to remove the shaft end
SPECIAL TOOL Play.
C-452 J9102-31
Fig. 19 Pinion Yoke Removal

CAUTION: Exercise care during the bearing preload
PINION
torque adjustment. Do not over-tighten, or loosen HOLDING TOOL
FLANGE
and then re-tighten the nut. Do not exceed the 6719
bearing preload torque. The collapsible preload
spacer on the shaft will have to be replaced. The
bearing preload torque will be re-adjusted after
ward.
(4) Install a socket and inch-pound torque wrench

on the pinion nut.
(5) Rotate the shaft with the torque wrench and
note the torque (Fig. 22).
The required preload torque is equal to the
amount recorded d u r i n g removal plus a n addi
tional 0.56 N-m (5 i n . lbs.).
Fig. 23 Tightening Pinion Shaft Nut

DIFFERENTIAL
REMOVAL
To service the differential the axle shafts must be
removed. Refer to the removal procedures in this
Group.
(1) Note the installation reference letters stamped
on the bearing caps and housing machined sealing
surface (Fig. 24).
INSTALLATION
REFERENCE LETTERS
J9303-10
Fig. 22 Check Pinion Rotation Torque

(6) Use Flange Wrench 6719 to retain the yoke
and shaft (Fig. 23). Tighten the shaft nut in very
small increments. J9G03-92
(7) Continue tightening the shaft nut in small
increments until the correct bearing rotation preload Fig. 24 Bearing Cap identification
torque is attained.
(8) Align the installation reference marks and (2) Remove the differential bearing caps.
attach the drive shaft to the yoke. (3) Position Spreader W-129-B with the tool dowel
(9) Add API grade GL 5 hypoid gear lubricant to pins seated i n the locating holes (Fig. 25). Install the
the differential housing, i f necessary. hold down clamps and tighten the tool turnbuckle
(10) Install wheel and tire assemblies. linger-tight.
(11) Lower the vehicle. (4) Install a pilot stud at the left side of the differ
ential housing. Attach Dial Indicator to housing pilot
stud. Load the indicator plunger against the opposite
side of the housing (Fig. 25) and zero the indicator.
BR DIFFERENTIAL A I D DRIVELINE 3 - 31
(8) Remove the case from housing. Mark or tag
bearing cups and outboard shim/spacer (selected
thickness) indicating which side they were removed.
DIFFERENTIAL INSTALLATION
(1) Position Spreader W-129-B with the tool dowel
pins seated in the locating holes (Fig. 25). Install the
hold down clamps and tighten the tool turnbuckle
finger-tight.
(2) Install a pilot stud at the left side of the differ
CAUTION: Do not spread over 0.38 mm (0.015 in). If

the housing is over-separated, it could be distorted
or damaged.
(3) Separate the housing enough to install the case

in the housing. Measure the distance with the dial
Fig. 25 Spread Differential Housing
indicator (Fig. 25).
CAUTION; Do not spread over 0.38 mm (0.015 In). If (4) Remove the dial indicator.
the housing is over-separated, it could be distorted (5) Install differential and outboard shim/spacer
or damaged. (selected thickness) in housing.
(6) Install case in the housing. Tap the differential
(5) Separate the housing enough to remove the case to ensure the bearings are fully seated (Fig. 27).
ease from the housing. Measure the distance with the Remove the spreader.
dial indicator (Fig. 25).
(6) Remove the dial indicator.
(7) Pry the differential case loose from the hous
ing. To prevent damage, pivot on housing with the
end of the pry bar against spreader (Fig. 26).
DIFFERENTIAL PRY BAR
J9302-19
Fig. 27 Differential Installation

(7) Install the bearing caps at their original loca
tions (Fig. 28). Tighten the bearing cap bolts to 77
N-m (57 ft. lbs.) torque.
Fig. 26 Differential Removal
3 - 32 DIFFERENTIAL AND DRIVELINE — — en
REMOVAL AMB I N S T A L L A T I O N (Continued)
STALLATION
REFERENCE LETTERS
HANDLE
C-4171
J9003-92
DIFFERENTIAL
Fig, 28 Differential Bearing Cap Reference Letters
DIFFERENTIAL SIDE BEARINGS BEARING
REMOVAL
(1) Remove Differential case from, axle housing.
(2) Remove the bearings from the differential case
with Press 938, and Adapter 1130 (Fig. 29). Fig. 30 Install Differential Side Bearings
AXLE SHAFT OIL SEAL
(1) Remove the axle shaft seal from the differential
housing with a long drift or punch. Be careful not
to damage housing.
(2) Clean the inside perimeter of the differential
housing with fine crocus cloth.
(3) Apply a light film of oil to the inside lip of the
BRIDGE new axle shaft seal.
938 (4) Install the inner axle seal (Fig. 31) or (Fig. 32).
TOOL
'1130 DIFFERENTIAL POSITION
HOUSING FOR OPEN-END
WRENCH
SPECIAL TOOL
DIFFERENTIAL' 5041-2
SPECIAL TOOL
Fig, 29 Differential Bearing Removal SPECIAL TOOL 5041-3
5041-7 J9402-21
DIFFERENTIAL SIDE BEARING INSTALLATION
If ring and pinion gears have been replaced, verify
differential side bearing preload and gear mesh back Fig. 31 Axle Seal installation—44 Axle
lash. INTERMEDIATE AXLE SHAFT
(1) Using tool C-4340 with handle C-4171, install
differential side bearings (Fig. 30). REMOVAL/DISASSEMBLY
(2) Install differential in axle housing. Service to the Disconnect axle seals and bearing
require the use of Tool Set 5041 (J34659) and Seal
Installer D-354.
BR — — — — — DIFFERENTIAL AND DRIVELINE 3 - 33
DIFFERENTIAL HOUSING POSITION SHIFT MOTOR
Fig. 32 Axle Seal Installation—60 Axle Fig. 34 Intermediate Shaft Bearing Installation
(1) Remove the vacuum motor housing. Refer to installer, if wrong installer is use axle will not
Shift Motor Removal in this section. seal.
(2) Remove the outer axle shaft. Refer to Hub
Bearing and Axle Shaft in this section. SHIFT MOTOR LOCATION
(3) Remove shift collar and intermediate axle HOUSING O P E N I N G AXLE FOR OPEN-END
SEAL
TUBE WRENCH
shaft.
(4) Remove the inner axle shaft seal from the shift
motor housing with a long drift or punch. Be careful
not to damage housing.
(5) Remove the intermediate axle shaft bearing
(Fig. 33).
SHIFT MOTOR AXLE LOCATION

HOUSING O P E N I N G TUBE FOR OPEN-END NUT
WRENCH
SPECIAL TOOL SPECIAL TOOL
BEARING 504144 SPECIAL TOOL 5041-2
5041-3
J9402-22
Fig. 35 Inner Axle Seal Installation—44 Axle
SHIFT MOTOR LOCATION

HOUSING O P E N I N G FOR OPEN-END
WRENCH
SPECIAL TOOL
5041-2
SPECIAL TOOL
NUT
D-354-2
J9402-18
Fig. 33 Bearing Removal Tool Installed

ASSEMBLY/INSTALLATION
(1) Position the bearing on installation tool. Seat
the bearing in the housing bore (Fig. 34). SPECIAL TOOL
SPECIAL TOOL 5041-2
(2) Clean the inside perimeter of the axle shaft
5041-60F SPECIAL TOOL
tube with fine crocus cloth. 5041-3
(3) Apply a light film of oil to the inside lip of the J9402-23
new axle shaft seal.
(4) Install the inner axle seal (Fig. 35) or (Fig. 36). Fig. 36 Inner Axle Seal Installation—60 Axle
The inner axle seal position is different on a (5) Insert the intermediate axle shaft into the dif
44 then a 60 axle. Be sure to use the correct ferential side gear.
(6) Install the shift collar on the splined end of the (2) Install new ring gear bolts and alternately
intermediate axle shaft. tighten to 95-122 N-m (70-90 ft. lbs.) torque (Fig.
(7) Lubricate the splined end of the intermediate 38).
axle shaft with multi-purpose lubricant. (3) Install differential in axle housing and verify
gear mesh and contact pattern.
CAUTION: Apply all-purpose lubricant to the axle
TORQUE
shaft splines to prevent damage to the seal during
axle shaft installation.
(8) Insert the axle shaft into the tube. Engage the
splined end of the shaft with the shift collar. Refer to
Hub Bearing and Axle Shaft in this section.
(9) Install the vacuum motor housing. Refer to
Shift Motor Installation i n this section.
RING GEAR
The ring and pinion gears are service in a matched
set. Do not replace the ring gear without replacing
the pinion gear. Refer to Pinion Gear removal and
installation paragraph in this section for proper pro
cedure.
REMOVAL
(1) Remove differential from axle housing.
(2) Place differential case in a suitable vise with
soft metal jaw protectors. (Fig. 37)
(3) Remove bolts holding ring gear to differential
case.
Fig. 38 Ring Gear Boit installation
(4) Using a soft hammer, drive ring gear from dif
ferential case (Fig. 37). PINION GEAR
REMOVAL
(1) Remove differential assembly from axle hous
ing.
Fig. 37 Ring Gear Removai

RING GEAR INSTALLATION
CAUTION: Do not reuse the bolts that held the ring

gear to the differential case. The bolts can fracture
causing extensive damage. G452 J9102-31
(1) Invert the differential case and start two ring Fig. 39 Pinion Yoke Removal
gear bolts. This will provide case-to-ring gear bolt
hole alignment.
(3) Remove the pinion gear from housing (Fig. 40). (7) Remove the rear bearing cup from housing
Catch the pinion with your hand to prevent it from (Fig. 42). Use Remover D-14S for model 44 or D-162
falling and being damaged. for model 60 and Handle C-4171.
RAWHIDE
HAMMER
DRIVER
HANDLE
J9302-25
Fig. 42 Rear Bearing Cup Removal
Fig. 40 Remove Pinion Gear
(8) Remove the collapsible preload spacer (Fig. 43).
(4) Remove the pinion gear seal with a slide ham
mer or pry out with bar.
(5) Remove oil slinger, front bearing.
(6) Remove the front pinion bearing cup and seal
with Remover D-147 for model 44 or D-158 for model COLLAPSIBLE
60 and Handle C-4171 (Fig. 41). SPACER
SHOULDER
REAR
BEARING
PINION
OIL GEAR
SLINGER
J9302-66
Fig. 43 Collapsible Spacer

HANDLE
(9) Remove the inner bearing from the pinion with
Splitter 1130 and Bridge 938 (Fig. 44).
REMOVER"'" J9302-22 (10) Remove the depth shims from the pinion gear
shaft. Record the thickness of the depth shims.
Fig. 41 Front Bearing Cup Removal
3 - 36 DIFFERENTIAL AND DRIVELINE — B R
INSTALLER HANDLE
Fig. 46 Pinion Front Bearing Cup Installation

(3) Install pinion front bearing, oil slinger. Apply a
light coating of gear lubricant on the lip of pinion
seal. Install seal with Installer D-163 and Handle
C-4171 (Fig. 47).
Fig. 44 inner Bearing Removal

*INION GEAR INSTALLATION
(1) Install the pinion rear bearing cup with
Installer D-145 for model 44 or D - l l l for model 60
and Driver Handle C-4171 (Fig. 45). Ensure cup is
correctly seated.
INSTALLER
INSTALLER
J9502-1

NOTE: Pinion depth shims are placed between the
rear pinion bearing cone and pinion gear to achieve
proper ring and pinion gear mesh. If the factory
installed ring and pinion gears are reused, the pin
HANDLE J9402-66 ion depth shim should not require replacement.
Refer to Pinion Gear Depth paragraph in this sec
Fig. 45 Pinion Rear Bearing Cup Installation tion to select the proper thickness shim before
(2) Install the pinion front bearing cup with installing rear pinion bearing cone.
Installer D-144 for model 44 or C-4203 for model 60
(4) Place the proper thickness depth shim on the
and Handle C-4171 (Fig. 46).
pinion gear and install the rear bearing. Refer to
BR — — DIFFERENTIAL AND DRIVELINE 3 - 37
R E M O V A L AND I N S T A L L A T I O N (Continued)
Pinion Gear Depth paragraph in Adjustments section
of this group.
(5) Install the rear bearing (and slinger i f used) on
the pinion gear with Installer W-262 for model 44 or
C-3095A for model 60 and an arbor press (Fig.. 48).
Fig. 50 Pinion Yoke Installation—Typical

(8) Install the yoke washer and a new nut on the
pinion gear. Tighten the nut to 258 N-m (190 ft. lbs.)
for model 44 or 291 N-m (215 ft. lbs.) for model 60
minimum. Do not over-tighten. Maximum torque
is 380 N-m (280 ft. lbs.).
CAUTION: Never loosen pinion gear nut to decrease

pinion gear bearing preload torque and never exceed
PINION G E A R
specified preload torque. If preload torque is exceeded
a new collapsible spacer must be installed. The torque
Fig. 48 Shaft Rear Bearing tnstaliation sequence will have to be repeated.
(6) Install a new collapsible preload spacer on pin (9) Use Flange Wrench 6719 to retain the yoke
ion shaft and install pinion gear in housing (Fig. 49). (Fig. 51). Slowly tighten the nut in small increments
until the rotating torque is achieved. Measure the
preload torque frequently. to avoid over-tightening
the nut.
80a0c4f5
Fig. 51 Tightening Pinion Nut

(10) Check bearing preload torque with an inch
pound torque wrench (Fig. 52). The torque necessary
Fig. 49 Collapsible Preload Spacer
to rotate the pinion gear should be:
(7) Install yoke with Installer W-162D for model 44 • Original Bearings — 1 to 3 N-m (10 to 20 in. lbs.).
or C-3716A for model 60 and Wrench 6719 (Fig. 50). • New Bearings — 2 to 5 N-m (15 to 35 in. lbs.).
Install the housing cover within 5 minutes
after applying the sealant.
(3) Install the cover on the differential with the
attaching bolts. Install the identification tag. Tighten
the cover bolts to 41 N-m (30 ft. lbs.) torque.
CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.
(4) Refill the differential housing with the speci
fied quantity of Mopar Hypoid Gear Lubricant.
(5) Install the fill hole plug and tighten to 34 N-m
AXLE SHAFT—CARDAN U-JOINT
DISASSEMBLY
Single cardan U-joints are not serviceable. I f defec
tive, they must be replaced as a unit. I f the bearings,
seals, spider or bearing caps are damaged or worn,
Fig. 52 Check Pinion Gear Rotation Torque replace the complete U-joint.
FINAL ASSEMBLY CAUTION: Clamp only the forged portion of the

(1) Install the axle shafts. Refer to Axle Shaft yoke in the vise. Also, to avoid distorting the yoke,
Installation within this group. do not over tighten the vise jaws.
(2) Scrape the residual sealant from the housing
and cover mating surfaces. Clean the mating surfaces (1) Remove the bearing cap retaining snap rings
with mineral spirits. Apply a bead of Mopar Silicone (Fig. 54).
Rubber Sealant on the housing cover (Fig. 53). Allow BEARING
the sealant to cure for a few minutes.
SNAP CAP
RINGS
J8902-15
Fig. 54 Axle Shaft Outer U-Joint
It can be helpful to saturate the bearing caps
with penetrating oil prior to removal.
(2) Locate a socket that is larger in diameter than
the bearing cap. Place the socket (receiver) against
Fig. 53 Typical Housing Cover With Sealant
the yoke and around the perimeter of the bearing cap
D I S A S S E M B L Y A N D A S S E M B L Y (Continued)
to be removed. Locate a socket that is smaller In (2) Rotate the differential side gears and remove
diameter than the bearing cap. Place the socket the pinion mate gears and thrust washers (Fig. 56).
(driver) against the opposite bearing cap. Position the
THRUST
yoke with the sockets in a vise (Fig. 55). WASHER
LARGE-
DIAMETER
SOCKET
WRENCH
MATE'GEAR SIDE GEAR J9203-61
J8902-16
Fig. 56 Pinion Mate Gear Removal
Fig. 55 Yoke Bearing Cap Removal (3) Remove the differential side gears and thrust
(3) Compress the vise jaws to force the bearing- cap washers.
into the larger socket (receiver).
(4) Release the vise jaws. Remove the sockets and DIFFERENTIAL ASSEMBLE
bearing cap that was partially forced out of the yoke. (1) Differential side gears and thrust washers
(5) Repeat the above procedure for the remaining (2) Pinion gears and thrust washers
bearing cap. (3) Pinion gear mate shaft (align holes in shaft
(6) Remove the remaining bearing cap, bearings, and case)
seals and spider from the propeller shaft yoke. (4) Lubricate all differential components with
hypoid gear lubricant.
ASSEMBLY (5) Install differential case in axle housing. Refer
(1) Pack the bearing caps 1/3 full of wheel bearing to Differential removal and installation procedure.
lubricant. Apply extreme pressure (EP), lithium-base
lubricant to aid i n installation.
(2) Position the spider in the yoke. Insert the seals
and bearings. Tap the bearing caps into the yoke
AXLE COMPONENTS
bores far enough to hold the spider In position.
Wash differential components with cleaning solvent
(3) Place the socket (driver) against one bearing
and dry with compressed air. Do not steam clean
cap. Position the yoke with the socket wrench in a
the differential components.
vise.
Wash bearings with solvent and towel dry, or dry
(4) Compress the vise to force the bearing caps
with compressed air. DO NOT spin bearings with
into the yoke. Force the caps enough to Install the
compressed air. Cup and bearing must be
retaining clips.
replaced as matched sets only.
(5) Install the bearing cap retaining clips.
Clean axle shaft tubes and oil channels i n housing.
(6) Install the axle shaft, refer to Hub Bearing and
Inspect for;
Axle Shaft installation.
• Smooth appearance with no broken/dented sur
faces on the bearing rollers or the roller contact sur
STANDARD DIFFERENTIAL
faces
DISASSEMBLE • Bearing cups must not be distorted or cracked
(1) Remove pinion gear mate shaft.
C L E A N I N G A N D I N S P E C T I O N (Continued)
• Machined surfaces should be smooth and with not use this surface for pinion depth setup or
out any raised edges checking (Fig. 58).
• Raised metal on shoulders of cup bores should
NNER PINION
be removed with a hand stone BEARING
• Wear and damage to pinion gear mate shaft,
pinion gears, side gears and thrust washers. Replace
as a matched set only.
• Ring and pinion gear for worn and chipped teeth
• Ring gear for damaged bolt threads. Replaced as
a matched set only.
• Pinion yoke for cracks, worn splines, pitted
STANDARD BUTTON END
areas, and a rough/corroded seal contact surface.
DEPTH
Repair or replace as necessary.
CENTERUNE OF
• Preload shims for damage and distortion. Install RING GEAR
new shims i f necessary.
ADJUSTMENTS J9403-56
PINION GEAR DEPTH Fig. 58 Pinion Gear Head

Compensation for pinion depth variance is
GENERAL INFORMATION achieved with select shims. The shims are placed
Ring and pinion gears are supplied as matched under the inner pinion bearing cone (Fig. 59).
sets only. The identifying numbers for the ring and
pinion gear are etched into the face of each gear (Fig. AXLE COLLAPSIBLE
57). A plus (+) number, minus (-) number or zero (0) HOUSINC SPACER
is etched into the face of the pinion gear. This num
ber is the amount (in thousandths of an inch) the
depth varies from the standard depth setting of a BEARING NION
pinion etched with a (0). The standard setting from CUP\ BEARING
the center line of the ring gear to the back face of the
pinion is 109.5 mm (4.312 inches) for Model 44 axles
and 127 mm (5 in.) for Model 60 axles. The standard
depth provides the best teeth contact pattern. Refer
to Backlash and Contact Pattern Analysis Paragraph
in this section for additional information. PINION
DEPTH
DRIVE PINION PINION
PRODUCTION GEAR DEPTH SHIM
NUMBERS VARIANCE GEAR
Fig. 59 Shim Locations

If a new gear set is being installed, note the
depth variance etched into both the original
and replacement pinion gear. Add or subtract
the thickness of the original depth shims to
compensate for the difference in the depth vari
ances. Refer to the Depth Variance charts.
Note where Old and New Pinion Marking columns
intersect. Intersecting figure represents plus or
minus amount needed.
GEAR MATCHING NUMBER For example, i f old pinion is plus (+) 1 and the new
(SAME AS RING GEAR NUMBER) J9003-100
pinion is minus (-) 3, intersecting figure is (+) 0.004
in. (0.10 mm). Add this amount to the original shim.
Fig. 57 Pinion Gear ID Numbers
Or i f the old pinion is (-) 3 and the new pinion is (-)
NOTE: The button end on the pinion gear head is 2, intersecting figure is (-) 0.001 in. (0.025 mm). Sub
no longer a rnachined-to-specifications surface. Do tract this amount from original shim. Refer to the
Pinion Gear Depth Variance Chart.
DIFFERENTIAL AND DRIVELINE 3 - 41
A D J U S T M E N T S (Continued)
PINION GEAR DEPTH VARIANCE
Replacement Pinion Gear Depth Variance

Gear Depth
] Variance I -.4 -3 -2 -1 0 +1 +2 + 3 +4
+ 4 + 0.006 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0
+ 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001
+ 2 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002
+ 1 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003
§ + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004
-1 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005
-2 1
+0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006
-3 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007

+ 0.001
^4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008
J8902-46
PINION DEPTH MEASUREMENT AMD DIAL INDICATOR

ADJUSTMENT
Pinion gear depth measurement is necessary PINION HEIGHT
when; BLOCK CONE
• Axle housing or differential case is replaced
• Pinion select shim pack is unknown
• Ring and pinion gears are replaced
Measurements are taken with pinion cups and pin
ion bearings installed in housing. Take measure
ments with Pinion Gauge Set 6730. Use Pinion Block
6734 for Model 44 and 6736 for model 60 axle. Use
Dial Indicator C-3339 dial indicator to measure dif SCREW
ference in height of the arbor and the pinion block.
(Fig. 60). • PINION BLOCK
(1) Assemble Pinion Gauge Set, Pinion Block and
pinion bearings. Install assembly into differential
SCOOTER BLOCK
pinion gear bore and hand tighten cone (Fig. 61).
(2) Place Arbor Disc 6732 on Arbor D-115-3 and
position in the bearing cradles (Fig. 62). Install dif ARBOR DISC
ferential bearing caps on Arbor Discs and tighten
caps snug only. J9403-45
Arbor Discs have different steps to fit other
axle sizes. Pick correct size step for axle being Fig. 60 Pinion Gear Depth Gauge Toois—Typical
serviced. The plunger travel distance indicated, plus or
(3) Firmly place Scooter Block D-115-2 and Dial minus the variance etched in the gear is the
Indicator on pinion height block tool and zero the required thickness for the depth shims.
dial indicator pointer. (5) Measure the thickness of each depth shim with
(4) Slide the Scooter Block across the arbor while a micrometer and combine the shims necessary for
observing indicator (Fig. 63). Record the longest total required shim pack thickness.Include oil
travel distance, whether inward (-) or outward (+), slinger or baffle thickness with the total shim
indicated by the pointer. pack thickness.
PINION BLOCK DIFFERENTIAL BEARING PRELOAD AND GEAR

LASH
DIFFERENTIAL SHIM PACK MEASUREMENT
NOTE: It is recommended whenever bearings are

removed that they be replaced.
o
(1) Install dummy side bearings D-345 for model
44 or D-343 for model 60 axles on differential.
(2) Install the differential case in the axle housing.
(3) Install the outboard shim/spacer (selected
thickness) on each side between bearing cup and
PINION HEIGHT
housing (Fig. 64). Use 0.142 in. (3.6 mm) as a start
BLOCK
ing point, shim/spacers are available i n various thick
J9403-39
nesses.
INSTALL
0.142-IN. (3.6-AAM) THICK
SHIM
EACH SIDE
PINION
HEIGHT BLOCK
Fig. 62 Gauge Toois in Housing—Typicai ® DIFFERENTIAL-

CASE J9003-27
ARBOR SCOOTER BLOCK
Fig. 64 Differential Bearing Shim Installation
(4) Install the marked bearing caps i n their correct
positions. Install and snug the bolts.
(5) Attach a dial indicator to the housing. Position
the indicator plunger so that it contacts the ring gear
mating surface (Fig. 65).
(6) Pry the differential case to one side and zero
the dial indicator pointer.
(7) Pry the differential case to the opposite side
and record indicator reading. Reading is additional
shim thickness needed for zero end play. For exam
ple, i f reading was 0.008 in. (0.20 mm), an additional
J9403-38 0.004-in. (0.10 mm) thick shim will be needed at
each side zero end play.
Fig. 63 Pinion Gear Depth Measurement—Typical (8) Install zero end-play shims on each side of
(6) Remove the measurement tools from the differ case.
ential housing. The differential bearings must be preloaded
to compensate for heat and load during opera
tion.
Fig. 66 Ring Gear Backlash Measurement
r — FOR MORE BACKLASH n
DECREASE SHIM INCREASE SHIM

Fig. 65 Shim Measurement
(9) Add an additional 0.004-in. (0.1 mm) to each,
outboard shim/spacer for bearing preload.
(11) Remove dummy bearings.
(12) Install new side bearing cones and cups.
(13) install ring gear.
(14) Install differential and verify gear lash and
contact pattern.
(15) Proceed to Final Assembly paragraph in this
section.
GEAR BACKLASH MMD CONTACT PATTERN

ANALYSIS
After installing new side bearings or ring and pin
ion set adjusting the bearing perload and gear mash
backlash will be necessary. J9302-28
(1) Rotate assembly several revolutions to seat
bearings. Measure backlash at three equally spaced Fig. 67 Backlash Shim Adjustment
locations around the perimeter of the ring gear with
a dial indicator (Fig. 66). tained within the specified limits until the correct
The r i n g gear backlash must be w i t h i n §.12 - tooth contact patterns are obtained.
0.20 mm (0.005 - 0.008 in.). It cannot vary more (2) Apply a thin coat of hydrated ferric oxide, or
than 0.05 mm (0.002 in.) between the points equivalent, to the drive and coast side of the ring
checked. gear teeth.
If backlash must be adjusted, spacers are available (3) Rotate the ring gear one complete revolution i n
in various thicknesses. Adjust the backlash accord both directions while a load is being applied. Insert a
ingly (Fig. 67). Do not increase the total shim pry bar between the differential housing and the case
pack thickness, excessive bearing preload and flange. This will produce distinct contact patterns on
damage will occur. both the drive side and coast side of the ring gear
The ring gear teeth contact patterns will show i f teeth.
the pinion gear depth shim(s) have the correct thick (4) Note patterns i n compound. Refer to (Fig. 68)
ness. I t will also show i f the ring gear backlash has for interpretation of contact patterns and adjust
been adjusted correctly. The backlash must be main- accordingly.
DRIVE SIDE COAST SIDE

OF RING OF RING
GEAR TEETH GEAR TEETH
DESIRABLE CONTACT PATTERN.

PATTERN SHOULD BE CENTERED
O N THE DRIVE SIDE O F T O O T H .
HEEL TOE TOE HEEL
PATTERN SHOULD BE CENTERED O N
THE COAST SIDE O F T O O T H ,
BUT MAY BE SLIGHTLY TOWARD
THE TOE. THERE SHOULD ALWAYS
BE SOME CLEARANCE BETWEEN
CONTACT PATTERN AND TOP O F
THE T O O T H .
RING GEAR BACKLASH C O R R E C T

T H I N N E R PINION GEAR DEPTH
SHIM REQUIRED.
RING GEAR BACKLASH CORRECT.

T H I C K E R PINION GEAR DEPTH
SHIM REQUIRED.
PINION GEAR DEPTH SHIM

CORRECT. D E C R E A S E RING
GEAR BACKLASH.

CORRECT I N C R E A S E RING
GEAR BACKLASH.
J9003-24
Fig. 68 Gear Tooth Contact Patterns

SPECIFICATIONS TORQUE
FRONT AXLE MODEL 44 AXLE
MODEL 44 DESCRIPTION TORQUE

Plug, Fill Hole 34 N-m (25 ft. lbs.)
DESCRIPTION SPEC. Bolt, Diff. Cover 42 N-m (31 ft. lbs.)
Axle Type Hypoid Bolt, Bearing Cap 108 N-m (80 ft. lbs.)
Lubricant Thermal Stable SAE 80W-90 Nut, Pinion 258-393 N-m (190-290 ft.lbs.)
Lube Capacity 2.28 L (4.8 pts.) Bolt, Ring Gear 95-122 N-m (70-90 ft. lbs.)
Axle Ratio 3.54, 3.55, 3.92, 4.09 Bolt, Shift Motor .11 N-m (8 ft. lbs.)
Ring Gear Diameter 215.9 mm (8.50 in.) Nut, Axle 237 N-m (175 ft. lbs.)
Pinion Standard Setting 109.5 mm (4.312 in.) Bolt, Wheel Brg 170 N-m (125 ft. lbs.)
Pinion Bearing Preload Nut, Lower Ball Stud 108 N-m (80 ft. lbs.)
Original Bearing 1-2 N-m (10-20 in. lbs.) Nut, Upper Ball Stud 101 N-m (75 ft. lbs.)
New Bearing 2.3-4.5 N-m (20-40 in. lbs.) Bolt, RWAL/ABS Sensor 11 N-m (96 in. lbs.)
MODEL 60 F R O N T AXLE MODEL 6 0 A X L E
DESCRIPTION SPEC. DESCRIPTION TORQUE

Axle Type Hypoid Plug, Fill Hole 34 N-m (25 ft. lbs.)
Lubricant Thermal Stable SAE 80W-90 Bolt, Diff. Cover 47 N-m (35 ft. lbs.)
Lube Capacity 3.61 L (122 oz.) Bolt, Bearing Cap 108 N-m (80 ft. lbs.)
Axle Ratio 3.54 4.10 Nut, Pinion 292-427 N-m (215-315 ft.lbs.)
Ring Gear Diameter 247.6 mm (9.75 in.) Bolt, Ring Gear 95-122 N-m (70-90 ft. lbs.)
Pinion Standard Setting 127 mm (5.000 in.) Bolt, Shift Motor 11 N-m (8 ft. lbs.)
Pinion Bearing Preload Nut, Axle 237 N-m (175 ft. lbs.)
Original Bearing 1-2 N-m (10-20 in. lbs.) Bolt, Wheel Brg 170 N-m (125 ft. lbs.)
New Bearing 2.3-4.5 N-m (20-40 in. lbs.) Nut, Lower Ball Stud 108 N-m (80 ft. lbs.)
Nut, Upper Ball Stud 101 N-m (75 ft. lbs.)
Bolt, RWAL/ABS Sensor 11 N-m (96 in. lbs.)
Driver—C-3716-A
Press, Ball Joint Remover/Installer—G-4212-F

S P E C I A L T O O L S (Continued)
Remover/Installer Set—D-354
Puller Head—938
BR ___ DIFFERENTIAL AND DRIVELINE 3 - 49
SPECIAL TOOLS (Continued)
Splitter, Bearing—1130
Receiver, Bail Joint—€289-6
Adapter, Bail Stud installer—6289-12
Receiver, Bail Stud—6289-1

Holder—6719
6730 PINION HEIGHT SET
6733 $734 6735 6736 6737 6738
Remover, Ball Stud—6289-8 Set, Pinion Depth Setting—6730

Remover—7794-A
Installer, Ball Joint—6758

INDEX
page page
GENERAL INFORMATION RING GEAR 62

AXLES 51 DISASSEMBLY AND ASSEMBLY
DIAGNOSIS AND TESTING STANDARD DIFFERENTIAL 65
DRIVELINE SNAP 53 TRAC-LOK DIFFERENTIAL 66
GEAR AND BEARING NOISE 53 CLEANING AND INSPECTION
GENERAL INFORMATION 51 AXLE COMPONENTS 69
LIMITED SLIP DIFFERENTIAL 54 DIFFERENTIAL CASE RUNOUT 70
LOW SPEED KNOCK 53 TRAC-LOK 70
REAR AXLE ALIGNMENT 54 ADJUSTMENTS
SERVICE DIAGNOSIS 55 DIFFERENTIAL BEARING PRELOAD AND
TRAC-LOK NOISE DIAGNOSIS 57 GEAR LASH 72
VIBRATION 53 PINION DEPTH MEASUREMENT AND
SERVICE PROCEDURES ADJUSTMENT 70
DRAIN AND REFILL 57 SIDE GEAR CLEARANCE MEASUREMENT AND
REMOVAL AND INSTALLATION ADJUSTMENT 75
AXLE ASSEMBLY 58 SPECIFICATIONS
AXLE SHAFT, SEAL AND BEARING 58 9 1/4 INCH AXLE 75
DIFFERENTIAL 62 TORQUE 75
EXCITER RING 63 SPECIAL TOOLS
PINION GEAR AND BEARINGS 63 9 1/4 AXLE 76
PINION SEAL 60
GENERAL INFORMATION DIAGNOSIS AND T E S T I N G
AXLES GENERAL INFORMATION

The 9 1/4-Inch axle housings consist of a cast iron Axle bearing problem conditions are usually caused
center section. They also have two steel axle shaft by:
tubes that are pressed into and welded to the differ • Insufficient or incorrect lubricant
ential housing (Fig. 1). • Foreign matter/water contamination
The removable, stamped steel cover provides a • Incorrect bearing preload torque adjustment
means for inspection and service without removing © Incorrect backlash (to tight)
the complete axle from the vehicle. When serviced, the bearings must be cleaned thor
Both axle types are equipped with a remote vent oughly. They should be dried with lint-free shop tow
fitting. els. Never spin dry bearings with compressed
A small, stamped metal axle gear ratio identifica air. This will overheat them and brinell the
tion tag is attached to the housing cover. bearing surfaces. This will result in noisy oper
The Rear Wheel Anti-lock (RWAL) brake speed sen ation after repair.
sor is attached to the top, forward exterior of the dif Axle gear problem conditions are usually the result
ferential housing. A seal is located between the of:
sensor and the wire harness connector. The seal • Insufficient lubrication
must be in place when the wire connector is • Incorrect or contaminated lubricant
connected to the sensor. The RWAL brake exciter • Overloading (excessive engine torque) or exceed
ring is press-fitted onto the differential case against ing vehicle weight capacity
the flange. • Incorrect clearance or backlash adjustment
Axles equipped with a Trac-Lok® differential are Insufficient lubrication is usually the result of a
optional. A Trac-Lok differential has a one-piece dif housing cover leak. It can also be from worn axle
ferential case, and the same internal components as shaft or pinion gear seals. Check for cracks or porous
a standard differential, plus two clutch disc packs. areas in the housing or tubes.
HUB AXLE DIFFERENTIAL

/ SHAFT HOUSING
Fig. 1 9 1/4 Axle

DIAGNOSIS AND TESTING {Continued!

Using the wrong lubricant will cause overheating tial. I f bearing noise occurs the pinion rear bearing is
and gear failure. Gear tooth cracking and bearing the source of the noise. I f the bearing noise is heard
spalling are indicators of this. during a coast, front bearing is the source.
Axle component breakage is most often the result Worn, damaged differential bearings usually pro
of: duce a low pitch noise. Differential bearing noise Is
• Severe overloading similar to pinion bearing. The pitch of differential
© Insufficient lubricant bearing noise Is also constant and varies only with
® Incorrect lubricant vehicle speed.
• Improperly tightened components Axle shaft bearings produce noise and vibration
Overloading occurs when towing heavier than rec when worn or damaged. The noise generally changes
ommended loads. Component breakage can occur when the bearings are loaded. Road test the vehicle.
when the wheels are spun excessively. Incorrect Turn the vehicle sharply to the left and to the right.
lubricant quantity contributes to breakage. Loose dif This will load the bearings and change the noise
ferential components can also cause breakage. level. Where axle bearing damage is slight, the noise
Incorrect bearing preload or gear backlash will not Is usually not noticeable at speeds above 30 mph.
result In component breakage. Mis-adjustment will
produce enough noise to cause service repair before a LOW SPEED KNOCK
failure occurs. I f a mis-adjustment condition is not Low speed knock is generally caused by a worn
corrected, component failure can result. U-joint or by worn side-gear thrust washers. A worn
Excessive bearing preload may not be noisy. This pinion gear shaft bore will also cause low speed
condition will cause high temperature which can knock.
result In bearing failure.
VIBRATION
GEAR AND BEARING NOISE Vibration at the rear of the vehicle is usually
caused by a: •
GEAR NOISE • Damaged drive shaft
Axle gear noise can be caused by insufficient lubri • Missing drive shaft balance weight
cant. Incorrect backlash, tooth contact, or worn/dam • Worn, out-of-balance wheels
aged gears can cause noise. • Loose wheel lug nuts
Gear noise usually happens at a specific speed • Worn U-joint
range. The range Is 30 to 40 mph, or above 50 mph. • Loose spring U-bolts
The noise can also occur during a specific type of • Loose/broken springs
driving condition. These conditions are acceleration, • Damaged axle shaft bearings
deceleration, coast, or constant lo.ad. • Loose pinion gear nut
When road testing, accelerate the vehicle to the • Excessive pinion yoke run out
speed range where the noise is the greatest. Shift • Bent axle shaft
'out-of-gear and coast through the peak-noise range. Check for loose or damaged front-end components
I f the noise stops or changes greatly, check for insuf or engine/transmission mounts. These components
ficient lubricant. Incorrect ring, gear backlash, or can contribute to what appears to be a rear-end
gear damage can cause noise changes. vibration. Do not overlook engine accessories, brack
Differential side and pinion gears can be checked ets and drive belts.
by turning the vehicle. They usually do not cause All driveline components should be examined
noise In straight-ahead driving. These gears are before starting any repair.
loaded during vehicle turns. I f noise does occur dur Refer to Group 22, Wheels and Tires for additional
ing vehicle turns, the side or pinion gears could be information.
worn or damaged. A worn pinion gear mate shaft can
also cause a snapping or a knocking noise. DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted
BEARING NOISE into gear (or the clutch engaged), can be caused by:
The axle shaft, differential and pinion gear bear ® High engine idle speed
ings can all produce noise when worn or damaged. • Loose engine/transmission/transfer case mounts
Bearing noise can be either a whining, or a growling • Worn U-joints
sound. • Loose spring mounts
Pinion gear bearings have a constant-pitch noise. • Loose pinion gear nut and yoke
This noise changes only with vehicle speed. Pinion • Excessive ring gear backlash
bearing noise will be higher because It rotates at a • Excessive side gear/case clearance
faster rate. Drive the vehicle and load the differen
3 - 54 DIFFERENTIAL H i DRIVELINE
DIAGNOSIS AND TESTING (Continued}

The source of a snap or a clunk noise can be deter (7) Average the FTR and the RTR distance mea
mined with the assistance of' a helper. Raise the vehi surements. Subtract the BTR measurement from this
cle on a hoist with the wheels free to rotate. Instruct average distance to obtain the camber. The accept
the helper to shift the transmission into gear. Listen able amount of camber is 1/16 inch to 3/32 inch (1.6
for the noise, a mechanics stethoscope is helpful in to 2.4 mm).
isolating the source of a noise.
NOTE; FTR + RTR Divided By two Minos BTR
REAR AXLE ALIGNMENT Equals Camber
MEASUREMENT I f the BTR distance measurement Is less than the

The following procedure can be used to determine average FTR and RTR distance measurement, the
if abnormal rear tire tread wear is the result of a camber will be positive ( + ). I f the BTR distance
bent or deformed rear axle shaft. measurement is greater than the average FTR and
(1) Raise both rear wheels off the surface with a RTR distance, the camber will be negative ( - ).
frame contact hoist. I f the toe position or camber Is not acceptable, a
(2) Attach a one-inch long piece of masking tape bent or deformed rear axle shaft is most likely the
at the center of each tire tread for use as reference cause.
marks.
(3) Rotate the rear wheels until both reference LIMITED SLIP DIFFERENTIAL
marks face the front of the vehicle. Measure the dis Under normal traction conditions, engine torque is
tance between the outside edges of the two pieces of divided evenly. With low-traction surfaces, engine
tape. Record this measurement as the Front Of Tire torque Is transferred to the wheel with the most tire
(FTR) measurement. traction. When diagnosing a limited-slip differential
(4) Rotate the rear wheels until both reference the wheel with the least traction can continue spin
marks face the rear of the vehicle. Measure the dis ning.
tance between the outside edges of the two pieces of The most common problem is a chatter noise when
tape. Record this measurement as the Rear Of Tire turning corners. Check for Incorrect or contaminated
(RTR) measurement. lubricant. Replace the gear lubricant i f necessary.
(5) Subtract the RTR measurement from the FTR • With Trac-Lok® differentials add a container of
measurement to obtain the amount of wheel toe. The Mopar Trac-Lok Lubricant.
acceptable rear wheel toe-in position is 1/18 in. (1.6 This will correct the condition in most instances. I f
mm) to 3/16 in. (4.8 mm) toe-out. the chatter persists, clutch damage could have
(6) Rotate the rear wheels until the reference occurred.
marks are facing downward. Measure the distance After changing the lubricant, drive the vehicle and
between the outside edges of the, two pieces of tape. make 10 to 12 slow, figure-eight turns. This maneu
Record this measurement as the Bottom Of Tire ver will pump lubricant through the clutches.
(BTR) measurement.
BR — ~ - DIFFERENTIAL AND DRIVELINE 3 - 55
SERVICE DIAGNOSIS SERVICE DIAGNOSIS
COMDSTION POSSIBLE CAUSES CORRECTION

bearings.
4. Excessive gear backlash 4. Check adjustment of ring gear backlash and pinion gear.
gear.
6. Loose drive pinion gearshaft 6. Tighten drive pinion gearshaft yoke nut with' specified torque.
yoke nut.
adjustment.
surfaces.
alignment.
4. Grabbing clutch. 4 Replace broken axle shaft. Inspect clutch and make necessary
DIFFERENTIAL C A S E 1. Improper adjustment of 1. Replace cracked case; examine gears and bearings for possible
4. Replace cracked case. After inspecting for other possible
DIFFERENTIAL G E A R S 1. Insufficient lubrication. 1. Replace scored gears. Scoring marks on the drive face of gear
2. Improper grade of lubricant. 2. Replace scored gears. Inspect all gears and bearings for
3. Excessive spinning of one 3. Replace scored gears. Inspect all gears, pinion bores and shaft
LOSS O F LUBRICANT 1. Lubricant level too high. 1. Drain excess lubricant by removing fill plug and allow lubricant
J9503-3
3 - 56 DIFFERENTIAL AND DRIVELINE ^ — BR
D I A G N O S I S AND T E S T I N G ( C o n t i n u e d ;
S E R V I C E DIAGNOSIS (CONT'D)
LOSS O F LUBRICANT 2. Worn axle shaft seals. 2. Replace worn seals.

4. Worn drive pinion gear shaft 4 Replace worn drive pinion gear shaft seal.
seal.
AXLE O V E R H E A T I N G 1. Lubricant level too low. 1. Refill differential housing.

lubricant.
necessary.
scoring.
G E A R TEETH BROKE 1. Overloading. 1. Replace gears. Examine other gears and bearings for possible
(RING G E A R A N D PINION) damage.
2. Erratic clutch operation. 2. Replace gears and examine the remaining parts for possible
damage. Avoid erratic clutch operation.
AXLE N O I S E 1. Insufficient lubricant. 1. Refill axle with correct amount of the proper lubricant.
bearings.
8. Loose differential bearing cap 8. Tighten with specified torque
bolts
J9503-4
D I A G N O S I S AND T E S T I N G ( C o n t i n u e d )
TRAC-LOK NOSSE DIAGNOSIS

If a noise occurs when turning corners, the most
probable cause is incorrect or contaminated lubri
cant. Before removing the Trac-lok unit for repair,
drain, flush and refill the axle with the specified
lubricant. Refer to Lubricant change in this Group.
A container of Trac-lok Lubricant (friction modifier)
should be added after repair service or a lubricant
change.
Vehicles with a limited slip differential should be
road tested by making 10 to 12 slow figure eight
turns. This maneuver will pump the lubricant
through the clutch discs to eliminate a possible chat
ter or pop noise complaint.
Refer to Group 0, Lubrication and Maintenance for
additional information. Fig. 2 Trzc-loc Test
(5) With standard differential, clean the differen
DIFFERENTIAL TEST
tial and the housing cavity with a flushing oil (or
light engine oil). This will remove the residual lubri
WARNING: WHEN SERVICING VEHICLES WITH A
cant and foreign matter.Do not use water, steam,
LIMITED SLIP DIFFERENTIAL DO NOT USE THE
kerosene or gasoline for flushing.
ENGINE TO TURN THE AXLE AND WHEELS. BOTH
(6) Scrape the residual sealant from the housing
REAR WHEELS MUST BE RAISED AND THE VEHI
CLE SUPPORTED. A LIMITED SLIP AXLE CAN and cover mating surfaces. Clean the mating surfaces
EXERT ENOUGH FORCE (IF ONE WHEEL IS IN with mineral spirits. Apply a bead of MOPAR Sili
CONTACT WITH THE SURFACE) TO CAUSE THE cone Rubber Sealant on the housing cover (Fig. 3).
VEHICLE TO MOVE. Allow the sealant to cure for a few minutes.
The differential can be tested without removing the
differential case by measuring rotating torque. Make
sure brakes are not dragging during this measure
ment.
(1) Engine off, transmission in neutral, and park
ing brake off.
(2) Place blocks in front and rear of both front
wheels.
(3) Raise one rear wheel until i t is completely off
the ground.
(4) Remove wheel and bolt Special Tool 6790 to
studs.
(5) Use torque wrench on special tool to rotate
wheel and read rotating torque (Fig. 2).
(6) I f rotating torque is less than 22 N-m (30 ft.
lbs.) or more than 271 N-m (200 ft. lbs.) on either
wheel the unit should be service.
SERVICE PROCEDURES
DRAIN AID REFILL Fig. 3 Typical Housing Cover

(1) Drive the vehicle until the gear lubricant NOTE: Install the housing cover within 5 minutes
reaches normal operating temperature. after applying the sealant. If not installed, the seal
(2) Raise and support the vehicle. ant must be removed and another bead applied.
(3) Remove the lubricant fill hole plug from the
differential housing cover. (7) Install the cover on the differential. Install the
(4) Remove the differential housing cover and drain identification tag. Tighten the cover bolts to 47 N-m
lubricant from the housing and axle shaft tubes. (35 ft. lbs.).

CAUTION: Overfilling the differential can result in (3) Connect the parking brake cables.
lubricant foaming and overheating. (4) Connect the brake fluid tube fittings to the
wheel cylinders. Bleed and adjust brakes refer to
(8) Refill the differential with the specified. quan Group 5 Brakes for procedure.
tity of Mopar Hypoid gear Lubricant. With Trac-Lok (5) Align the installation reference marks and con
differentials, add a container of friction modifier. nect the drive shaft yoke to the pinion yoke. Tighten
(9) Install the fill hole plug. the U-joint clamp bolts to 19-23 N-m (170-200 in.
(10) Road test the vehicle. lbs.) torque.
(6) Install wheel and tire assemblies.
AXLE SHAFT, SEAL AND BEARING
AXLE ASSEMBLY
It is not necessary to remove the complete axle CAUTION: When rear axle service is necessary, both
from the vehicle for routine differential inspection rear wheels must be raised off the surface so that they
and service. I f the differential housing, case or axle are free to rotate. Be cautious when the tires are being
shaft tubes are damaged the complete axle can be rotated by the engine or by other means.
removed and replaced.
REMOVAL AXLE SHAFT REMOVAL

(1) Raise and support vehicle. (1) Raise and support the vehicle.
(2) Block the brake pedal in the up (non-de (2) Remove wheel and tire assembly.
pressed) position with a wooden block. (3) Remove the brake drum.
(3) Remove the rear wheels and brake drums. (4) Clean all the foreign material from housing
(4) Disconnect the brake fluid tube fittings from cover area.
the wheel cylinders. Cap the fittings to prevent loss (5) Loosen the housing cover bolts. Drain the lubri
of brake fluid. cant from the housing. Remove the housing cover.
(5) Remove the vent hose from the brake tee nip (6) Rotate the differential case so the pinion mate gear
ple. shaft lock screw is accessible. Remove the lock screw and
(6) Remove the brake tee bolt. Carefully detach the pinion mate gear shaft from the case (Fig. 4).
the brake fluid tubes from the clips.
PINION
(7) Disconnect the parking brake cables and unbolt
backing plates.
Mark the U-joint, pinion yoke, and pinion
shaft for reference.
(8) Disconnect the drive shaft from the pinion
yoke. Secure the drive shaft in an upright position to
prevent damage to the rear U-joint.
(9) Remove the shock absorber lower attaching
nuts and bolts.
(10) Support axle and remove rear spring U-bolts
and the spring brackets.
W A R N I N G : AXLE MAY R O T A T E O N S U P P O R T
WHEN S P R I N G CLAMP BOLTS A R E R E M O V E D
ENSURE AXLE IS SECURED ON SUPPORT.
(11) Remove the axle assembly from the vehicle.

(12) Wash and clean the outer surface of the hous
ing and tubes. Use an appropriate cleaning solution
and dry the surface with compressed air.
INSTALLATION Fig. 4 Pinion Mate Shaft Lock Screw

(1) Position the rear axle spring pads over the
spring center bolts.
(2) Install the spring clamp bolts and nuts, and
shock absorber lower bolts. Tighten the nuts to the
specified torque.
BR ™ ~ ™ — — — DIFFERENTIAL AND DRIVELINE 3 - 59
HEllOWAL A M P INSTALLATION ( C o n t i n u e d !
(7) Push the axle shaft in toward the center of the SEAL AND BEARING REMOVAL
vehicle. Remove the axle shaft C-clip lock from the (1) Remove the axle shaft seal with a small pry
axle shaft (Fig. 5 ) . bar (Fig. 7).
Fig. 7 Axle Seal Removal

(2) Remove the axle bearing with Remover 0-4828
(Fig. 8)
Fig. 5 Axle Shaft C-Clip Lock

(8) Remove the axle shaft. Use care to prevent
damage to the axle shaft bearing.
(9) Inspect the axle shaft bearing contact surface
area for indications of wear (Fig. 6).
Fig. 8 Bearing Removal

(3) Inspect the axle shaft seal surface and tube
bore for roughness and burrs. Polish each axle
shaft w i t h No. 600 crocus cloth. This w i l l
remove slight surface damage. Do not reduce
the diameter of the axle shaft seal contact sur
face. When polishing, the crocus cloth should
be moved around the circumference of the
Fig. 6 Axle Shaft Bearing
shaft (not in-line w i t h the shaft).
NOTE: If wear exists, the axle shaft and bearing
should be replaced. Normal bearing contact on the
shaft will be a dull gray and it could appear to be
lightly dented.
(10) I f any of these conditions exist, the axle shaft

and bearing must be replaced.
3 • 60 DIFFERENTIAL AND DRIVELINE BR
REMOVAL AND I N S T A L L A T I O N (Continued)

BEARING AND SEAL INSTALLATION (8) Remove the fill hole plug and fill the differen
tial housing with lubricant. Refer to the Specifica
NOTE; Always install a new seal. tions chart for the type and the quantity. Install the
fill hole plug.
(1) Wipe the axle shaft tube bore clean.
(2) Install a new bearing with Installer 0-4826 PINION SEAL
with Handle C-4171
(3) Ensure that the bearing is not cocked and Is CAUTION: The following procedures must be used
seated firmly against the tube shoulder. so the correct pinion bearing preload torque is
retained. If not followed completely, failure of the
CAUTION: DO NOT use the new axle shaft seal to rear axle can result.
position or seat the bearing in the axle shaft bore,
(4) Install the new axle shaft seal (Fig. 9) with REMOVAL
Installer C-4826 and Handle C-4171. (1) Raise and support the vehicle.
(2) Scribe a mark on the U-joint, pinion yoke, and
pinion shaft for reference.
(4) Remove the wheel and tire assemblies and
remove the brake drums to prevent any drag. The
drag may cause a false bearing preload torque mea
surement.
(5) Use a Newton-meter or an inch-pound torque
wrench to measure the pinion bearing preload.
Rotate the pinion shaft several times with the torque
wrench. Note the indicated torque as the wrench is
moved through several revolutions.
NOTE: This measurement is critical for bearing pre

load torque which must b e re-adjusted after the
Fig. 9 Axle Shaft Seal installation
new seal is installed.
(5) When the tool contacts the tube end (face), the
seal is position to the correct depth. (6) Hold the yoke with Wrench 6719. Remove the
pinion shaft nut and Belleville washer.
A X L E SHAFT INSTALLATION (7) Remove the yoke with Remover C-452 (Fig. 10).
(1) Lubricate the bearing bore and seal lip. Insert
the axle shaft and engage the splines with the side
gear. Use care to prevent the shaft splines from
damaging the axle shaft seal l i p .
(2) Insert C-clip lock in the recessed groove of the
axle shaft. Push the axle shaft outward to seat the
C-clip lock.
(3) Insert pinion gear mate shaft in the case
through the thrust washers and pinion gears. Align
the hole in the shaft with the lock screw hole. Install
the lock screw with Loctite® on the threads. Tighten
the screw to 11 N-m (8 ft. lbs.) torque.
(4) Clean the cover and apply a bead of sealant C452
and install cover.
(5) Install the brake drum.
(6) Install wheel and tire assembly and lower the
vehicle.
Fig. 10 Yoke Removal
(7) Raise or lower the hoist until the vehicle is
level.
lR . _ _ _ _ _ _ _ _ _ _ DIFFERENTIAL AND DRIVELINE 3 - 61
E M O V A L AND INSTALLATION (Continued)

(8) Remove the pinion shaft seal with Puller 0-748 DIFFERENTIAL
(Fig. 11).
C-748
J9403-20
. Fig. 12 Tightening Pinion Shaft Nut
, Fig. 11 Pinion Seal Removal
CAUTION: Never loosen pinion gear nut to
INSTALLATION decrease pinion gear bearing preload torque and
(1) Clean the seal contact surface in the housing never exceed specified preload torque. If preload
bore. torque is exceeded a new collapsible spacer must
(2) Examine the splines on the pinion shaft for be installed. The torque sequence will have to be
burrs or wear. Remove any burrs and clean the shaft. repeated.
(3) Inspect pinion yoke for cracks, worn splines and
worn seal contact surface, replace yoke i f necessary. (10) Continue tightening and measuring the bear
ing preload torque until the torque is the same as the
NOTE: The outer perimeter of the seal is pre-coated original. The bearing preload torque should
with a special sealant. An additional application of never be greater than 1 N«m (10 in. lbs.) more
sealant is not required. than the recorded value.
(4) Install'the new pinion shaft seal with Installer NOTE: The bearing preload torque should be con
C-3980A or C-4109A and Handle C-4735 stant during a complete revolution of the pinion. If
the preload torque varies, this indicates a binding
NOTE: The seal is correctly installed when the seal condition. This condition must be corrected before
flange contacts the face of the differential housing installation of the drive shaft.
flange.
(11) I f the specified torque is not obtained, tighten
(5) Position the pinion yoke on the end of the shaft the nut in small increments until the preload torque
with the reference marks aligned. is obtained.
(6) Seat yoke on pinion shaft with Installer (12) The seal replacement is unacceptable i f the
W-162D and Wrench 6719 final nut torque is less than 285 N-m (210 ft. lbs.).
(7) Remove the tools and Install the Belleville (13) Install the drive shaft with the installation
washer. The convex side of the washer must face out reference marks aligned. Tighten the U-joint yoke
ward. clamp screws to 19 N-m (14 ft. lbs.).
(8) Hold pinion yoke with Yoke Holder 6719 and (14) Install the brake drums.
tighten shaft nut to 285 N-m (210 ft. lbs.) (Fig. 12). (15) Install wheel and tire assemblies and lower
Rotate pinion shaft several revolutions to ensure the the vehicle.
bearing rollers are seated. (16) Check the differential housing lubricant level.
(9) Use a Newton-meter or an inch-pound torque
wrench to measure the pinion bearing preload
torque.
DIFFERENTIAL REFERENCE REFERENCE

MARKS MARK
It is not necessary to remove the complete axle to
service the differential.
REMOVAL
(1) Remove the axle shafts, refer to Axle Shaft
Removal.
Side play resulting from bearing races being
loose on case hubs requires replacement of the
differential case. Otherwise, use threaded
adjuster to remove the side play before measur
ing the r i n g gear runout.
(2) Attach Dial Indicator to Pilot stud C-3288B.
Place the indicator plunger at a right angle (90°) to
the ring gear (Fig. 13). J9403-11
Fig. 14 Mark For instaiiation Reference

AXLE
TUBE
DIAL
INDICATOR 19403-12
Fig. 18 Ring Gear Runout Measurement J9403-3

(3) Measure runout by turning the ring gear sev
eral complete revolutions. Observe dial indicator and Fig, 15 Threaded Adjuster Tool
mark the ring gear and differential case at maximum DIFFERENTIAL INSTALLATION
runout areas. The ring gear runout should not exceed (1) Apply a coating of hypoid gear lubricant to the
0.005 inch (0.13 mm). I f runout exceeds 0.005 Inch differential bearings, bearing cups and threaded
(0.13 mm), a damaged differential case could be the adjusters. A dab of grease can be used to keep the
cause. adjusters in position. Carefully position the assem
The m a r k i n g on the differential case w i l l be bled differential case in the housing.
very useful later d u r i n g the differential case (2) Observe the reference marks and install the
runout. differential bearing caps at their original locations
(4) Remove RWAL/ABS sensor from housing. (Fig. 16).
(5) Mark the differential housing and the differen (3) Install the bearing cap bolts (Fig. 16). Tighten
tial bearing caps for installation reference (Fig. 14). the upper bolts to 14 N-m (10 ft. lbs.) torque. Tighten
(6) Remove bearing threaded adjuster lock from the lower bolts finger-tight until the bolt head is
each bearing cap. Loosen the bolts, but do not lightly seated.
remove the bearing caps.
(7) Loosen the threaded adjusters with Wrench Him GEAR
C-4164 (Fig. 15). The ring and pinion gears are service in a matched
(8) Hold the differential case while removing bear set. Do not replace the ring gear without replacing
ing caps and adjusters. the pinion gear. Refer to Pinion Gear removal and
(9) Remove the differential case. installation paragraph in this section for proper pro
Each differential bearing cup and threaded cedure.
adjuster must be kept with their original bear
ing cone.
bearing preload, and gear lash will require adjust
ment.
EXCITER RING
REMOVAL
The ring gear must be removed before the RWAL/
ABS brake exciter ring can be replaced.
(1) Remove exciter ring with a hammer and drift.
INSTALLATION
(1) Heat the replacement exciter ring with a heat
lamp or by immersing in a hot fluid. The tempera
ture should not exceed 149°C (300°F). Do not use a
torch to heat the ring.
(2) After heating, quickly position the exciter ring
on the differential case adjacent to the flange.
Fig. 16 Bearing Caps & Bolts
PILOT
REMOVAL
(2) Place differential case In a suitable vise with
soft metal jaw protectors.
(3) Remove bolts holding ring gear to differential
case.
(4) Using a soft hammer, drive ring gear from dif
ferential case.
RING GEAR INSTALLATION
CAUTION: Do not reuse the bolts that held the ring

gear to the differential case. The bolts can fracture
causing extensive damage.
(1) Using a suitable solvent, wash oil residue from

differential case and ring gear. Fig. 17 EXCITER RING
(2) Using a suitable file, remove burrs or sharp PINION GEAR AND BEARINGS
edges that may cause ring gear to not mate flush Before removing the pinion flange, measure and
with differential and exciter ring. record the rotation resistance of the pinion gear
(3) Thread two pilot studs C-3288-B in ring gear using a torque wrench. Use this measurement when
180° across from each other to aid alignment. installing the pinion gear using the original bearings.
CAUTION: Do not use open flame to heat ring gear, REMOVAL
damage to ring gear can result. (1) Remove pinion gear nut and washer. Use
Puller C-452 and Wrench C- 3281 to remove the pin
(4) Using a heat lamp or paint stripping heat gun, ion yoke.
warm ring gear to no greater than 150° C (300° F). (2) Drive pinion gear out of housing with plastic or
(5) Invert the differential case and start two ring rawhide hammer. This will damage the front
gear bolts. This will provide case-to-ring gear bolt bearing rollers and bearing cup. The front
hole alignment. bearing and cup must be replaced.
(6) Install new ring gear bolts and draw ring gear (3) Remove the collapsible preload spacer
to exciter ring. (4) Remove the pinion seal with Puller C-748.
(7) Place differential case i n a suitable vise with (5) Remove the front and rear bearing cups with
soft metal jaw protectors. Remover Set C-4306 and Handle C-4171.
(8) Alternately tighten bolt holding ring gear to (6) Remove rear bearing from pinion shaft (Fig.
differential to 102 N-m (75 ft. lbs.) torque. 18). Remove and record the pinion gear depth shims.
When installing differential in axle housing after (7) Using remover C-4306 and handle C-4171,
ring and pinion gear replacement, pinion depth, side remove rear pinion bearing cups from axle housing.
REMOVAL AN© INSTALLATION (Continued)

(8) Using remover D-103, remove front pinion
bearing cups from axle housing.
PRESS
SPECIAL TOOL
938
SPECIAL
TOOL
C-3095A
PINION
BEARING
SPECIAL TOOL
1130
PINION
J9403-5O
Fig. 19 Shaft Rear Bearing Installation

J9403-44
YOKE
Fig. 18 inner Bearing Removai INSTALLER
PINION GEAR INSTALLATION
Determine the proper pinion depth shim thickness
using Pinion Depth Measurement paragraph in the
Adjustment section of this group.
(1) Using installer D-129 and handle C-4171,
install front pinion bearing cup in axle housing.
(2) Using installer tool C-4306 and handle C-4171,
install rear pinion bearing cup in axle housing.
(3) Position depth shim(s) on pinion gear shaft and
install rear bearing with Installer C-3095A (Fig. 19).
(4) Install front pinion bearing and install pinion
shaft seal with Installer C-4109A and Handle
C-4735.
YOKE
HOLDER
NOTE: The outer perimeter of the seal is pre-
-coated with a special sealant. An additional appli
cation of sealant is not required.
(5) Lubricate the pinion gear front and rear bear J9402-61
ings with gear lubricant.
(6) Install new collapsible spacer on pinion gear Fig. 20 Pinion Yoke Installation
shaft. Install pinion gear in housing.
(9) Install the Belleville washer. The convex side of
CAUTION: Use care to prevent over collapsing pre the washer must face outward. Install the pinion nut.
load spacer during installation of the yoke and seat (10) Retain pinion yoke with Holder 6719. Initially
ing the front bearing. tighten the drive pinion gear shaft nut enough to
remove the bearing end play While tightening, rotate
(7) Install the pinion yoke with Installer W-162D the pinion shaft to ensure the bearing rollers are cor
and Holder 6719 (Fig. 20). rectly seated.
(8) Remove tools from the pinion gear. (11) Tighten the pinion nut to (Fig. 21) 285 N-m
(210 ft. lbs.) torque (minimum).

DIFFERENTIAL
Fig. 22 Bearing Preload Torque Measurement

ft. lbs.) torque. If preload torque is not within
the specified range this is also unacceptable.

Fig. 21 Tightening Pinion Gear Nut
STANDARD DIFFERENTIAL
(12) Remove the tools from the shaft. Rotate the
pinion several complete revolutions (both directions) DISASSEMBLE
to additionally seat the bearing rollers. (1) Remove pinion gear mate shaft.
(2) Rotate the differential side gears and remove
CAUTION: Do not loosen pinion gear nut to
the pinion mate gears and thrust washers (Fig. 23).
decrease pinion gear bearing preload or exceed
specified preload torque. If preload torque is THRUST
exceeded a new collapsible spacer must be WASHER
installed. The tightening sequence must be
repeated.
(13) Measure the pinion bearing preload torque by

rotating pinion shaft with a torque wrench. The cor
rect bearing preload torque is 2-4 N-m (20-30 In.
lbs.). This torque value is with replacement bearings
and pinion nut tightened to a minimum of 285 N-m
(210 ft. lbs.) torque (Fig. 22)
When using original p i n i o n rear bearing and
a replacement front bearing. The correct pre
load torque Is 1 N»m (10 in. lbs.) torque plus the
torque measured and recorded during disas
sembly.
The bearing preload torque should be con
stant during a complete revolution of the drive
pinion gear shaft. If preload torque varies
while rotating the shaft, there is an internal
binding that must be corrected before assem MATE G E A R SIDE G E A R J9203-61
bly.
(14) I f specified torque is not obtained, tighten the Fig. 23 Pinion Mate Gear Removai
nut in small increments until preload torque is (3) Remove the differential side gears and thrust
obtained. washers.
The differential will be unacceptable for use
if the final nut torque is less than 285 N«m (210
3 - II DIFFERENTIAL AND DRIVELINE BR
DIFFERNTIAL THRUST WASHER

CASE
PINION
SNAP RING
SHAFT
LOCK
PIN
CLUTCH PACK
PINION
MATE
SHAFT J9203-13
Fig. 24 Trac-lok Differential Components

DIFFERENTIAL ASSEMBLE RING GEAR
(1) Differential side gears and thrust washers BOLTS UPWARD
(2) Pinion gears and thrust washers
(3) Pinion gear mate shaft (align holes in shaft
and case)
(4) Lubricate all differential components with
(5) Install differential case in axle housing. Refer
to Differential removal and installation procedure.
TRAC-LOK DIFFERENTIAL
The Trac-Lok (limited-slip) differential compo DIFFERENTIAL
ON AXLE
nents are illustrated in (Fig. 24). Refer to this illus SHAFT
tration during repair service.
DISASSEMBLY
Service to the Trac-Lok differential requires the
use of Tool Set 6960. Refer to Model 35 Axle section
in this Group for Differential Removal and Installa
tion. J8903-43
(1) Clamp Side Gear Holding Tool 6965 in a vise.
(2) Position the differential case on the holding Fig. 25 Differential Case Holding Tool
tool (Fig. 25). Place shop towels under the differen
tial to avoid damage i f removal of the ring gear is (6) Install and lubricate Step Plate 6960-3 (Fig.
required (Fig. 25). 29).
(7) Assemble Threaded Adapter 6960-1 into top
(3) I f ring gear replacement is required, remove
and discard the bolts holding the ring gear to the side gear. Thread forcing Screw 6960-4 into adapter
case. Tap the ring gear with a rawhide or plastic until i t becomes centered in adapter plate.
mallet and separate ring gear from case (Fig. 26). (8) Position a small screw driver in slot of
(4) Remove the pinion gear mate shaft lock screw Threaded Adapter 6960-1 (Fig. 30) to prevent
(Fig. 27), adapter from turning.
(5) Remove the pinion gear mate shaft. I f neces
sary, use a drift and hammer (Fig. 28).
BR • DIFFERENTIAL AND DRIVELINE 3 - 67
Fig. 28 Mate Shaft Removal

(9) Tighten forcing screw tool 122 N-m (90 ft. lbs.)
(maximum) to compress Belleville springs In clutch
packs (Fig. 31).
Fig. 33 Pinion Gear Removal
SIDE GEAR DIFFERENTIAL

AND CLUTCH DISC . CASE
Fig. 31 Tighten Beileviiie Spring Compressor Toot
(10) Using a 0.020 in. feeler gauge and mallet,
remove thrust washers from behind the pinion gears
(Fig. 32).
Fig. 34 Side Gear & Clutch Disc Removal

(14) Remove case from fixture. Remove remaining
clutch pack.
(15) Remove clutch pack retaining clips. Mark
each clutch pack for installation reference.
ASSEMBLY
Fig. 32 Remove Pinion Thrust Washer
The clutch discs are replaceable as complete sets
(11) Loosen the forcing screw tool until the clutch only. If one clutch disc pack is damaged, both
pack tension is relieved and the pinion gears can be packs must be replaced.
slightly rattled between the case and side gears. Lubricate each component with gear lubricant
(12) Insert Turning Bar 6960-2 in case. Rotate before assembly.
case with tool until pinion gears can be removed (Fig. (1) Assemble the clutch discs into packs secure
33). disc packs with retaining clips (Fig. 35).
(13) Remove top side gear and clutch pack. Keep (2) Position assembled clutch disc packs on the
plates in correct order during removal (Fig. 34). side gear hubs.
(3) Position case on axle fixture.
B R — — • • • — DIFFERENTIAL AND D1I1EL1NE 3 - 69
CLUTCH PACK UPPER SIDE

GEAR AND CLUTCH
DISC PACK
DIFFERENTIAL
CASE
RETAINER
J8903-50
Fig. 35 Clutch Disc Pack

Fig. 37 Upper Side Gear & Clutch Disc Pack
(4) Install clutch pack and side gear in lower bore Installation
(Fig. 36). Be sure clutch pack r e t a i n i n g clips
(10) Rotate case with Turning Bar 6960-2 until
remain i n position and are seated I n the case
mate shaft holes in pinion gears align with holes in
pockets.
case.
(11) Tighten forcing screw to 122 N-m (90 ft. lbs.)
to compress the Belleville springs. Lubricate and
install thrust washers behind pinion gears and align
washers with a small screw driver. Insert mate shaft
into each pinion gear to verify alignment.
(12) Remove forcing screw, threaded adapter and
step plate. Install pinion gear mate shaft, align holes
in shaft and case.
(13) Install the pinion mate shaft lock screw finger
tight to hold shaft during installation.
If replacement gears and thrust washers were
installed, it is not necessary to measure the
gear backlash. Correct fit is due to close
machining tolerances during manufacture.
(14) Lubricate all differential components with
Fig. 36 Clutch Discs & Lower Side Gear installation
(5) Install lubricated Step Plate 6960-3 on first CLEANING AND INSPECTION
clutch pack (Fig. 37).
(6) Install the upper side gear and clutch disc pack AXLE COMPONENTS
(Fig. 37). Wash differential components with cleaning solvent
(7) Hold assembly in position. Insert Threaded and dry with compressed air. Do not steam clean
Adapter 6960-1 into top side gear, insert forcing the differential components.
Screw 6960-4. Wash bearings with solvent and towel dry, or dry
(8) Tighten forcing screw tool to slightly compress with compressed air. DO NOT spin bearings with
clutch discs. compressed air. Cup and bearing must be
(9) Place pinion gears in position in side gears and replaced as matched sets only.
verify that mate shaft hole line up. Clean axle shaft tubes and oil channels in housing.
CLEANING AND INSPECTION ( C o n t i n u e d )

Inspect for; runout exceeds this amount replace the differential
• Smooth appearance with no broken/dented sur case.
faces on the bearing rollers or the roller contact sur To reduce r i n g gear r u n o u t positioning the
faces r i n g gear r u n o u t m a r k 18(1 degrees opposite the
• Bearing cups must not be distorted or cracked flange r u n o u t mark.
• Machined surfaces should be smooth and with (5) Remove the differential bearing cap bolts.
out any raised edges Remove the differential case from the differential
• Raised metal on shoulders of cup bores should housing.
be removed with a hand stone
• Wear and damage to pinion gear mate shaft, TRAC-LOK
pinion gears, side gears and thrust washers. Replace (1) Clean all components in cleaning solvent. Dry
as a matched set only. components with compressed air.
• Ring and pinion gear for worn and chipped teeth (2) Inspect clutch pack plates for wear, scoring or
• Ring gear for damaged bolt threads. Replaced as damage. Replace both clutch packs i f any one compo
a matched set only. nent in either pack is damaged.
• Pinion yoke for cracks, worn splines, pitted (3) Inspect side and pinion gears. Replace any gear
areas, and a rough/corroded seal contact surface. that is worn, cracked, chipped or damaged.
Repair or replace as necessary. (4) Inspect differential case and pinion shaft.
• Preload shims for damage and distortion. Install Replace i f worn or damaged.
new shims i f necessary.
PRESOAK PLATES AND DISC
DIFFERENTIAL CASE RUNOUT Plates and discs with fiber coating (no grooves or
(1) I f the ring gear runout exceeded 0.005 Inch lines) must be presoaked in Friction Modifier before
(0.13 mm), case flange runout should be measured. assembly. Soak plates and discs for a minimum of 20
Install the case with the bearing cups and the minutes. Add remaining Friction Modifier to differen
threaded adjusters close to their original position. tial after assembly.
(2) Install the bearing caps and bolts. Tighten the
bolts lightly. Use Wrench C-4164 to thread both
ADJUSTMENTS
adjusters inward. Remove all side play.
(3) Attach Dial Indicator to measure the flange
PINION DEPTH MEASUREMENT AND ADJUSTMENT
runout. The plunger should contact the ring squarely
Pinion depth measurement is taken with Tool Set
between the outer edge and the gear attaching bolt
C-758-D6 with new pinion bearing cups Installed.
holes (Fig. 38).
© Position Spacer (SP-6017) over Shaft (SP-526)
o Position pinion rear bearing on shaft
• Position tools (with bearing) in the housing
• Install Sleeve (SP-1730)
• Install pinion front bearing
• Install Spacer (SP-6022)
• Install Sleeve (SP-535-A), Washer (SP-534) and
Nut (SP-533)
(1) Tighten the nut to seat the pinion bearings in
the housing. Allow the sleeve to turn several times
during the tightening to prevent brinelling the bear
ing cups or the bearings.
Depth shim(s) are positioned between the
pinion gear rear bearing and pinion gear to
provide the separation distance. The required
thickness of the depth shim(s) is determined
according to the following information.
Fig. 38 Case Flange Runout Measurement (2) Loosen the compression nut tool. Lubricate the
pinion gear front and rear bearings with gear lubri
(4) Rotate the differential case several times and
cant. Re-tighten the compression nut tool to 1-3 N-m
observe the dial indicator. Mark the area of maxi
(15-25 in. lbs.) torque. Rotate the pinion gear several
mum flange runout. The differential case flange
runout must not exceed 0.003 inch (0.08 mm). I f the complete revolutions to align the bearing rollers.
• Install Gauge Block SP-6020 at the end of
SP-526
BR ————-—_ ^ - DIFFERENTIAL AND DRIVELINE 3 - 71
ADJUSTMENTS (Continued)
Fig. 89 Gauge Block Fig. 40 Depth Shim(s) Selection

• Install Cap Screw (SP-536) and tighten with (6) Note the etched number on the face of the
Wrench SP-531 (Fig. 39). drive pinion gear ( - 1 , -2, 0, +1, +2, etc.). The num
(3) Position Crossbore Arbor SP-6018 In the differ bers represent thousands of an inch deviation from
ential housing. the standard. I f the number is negative, add that
(4) Center the tool and place a piece of 0.002 inch value to the required thickness of the depth shim(s).
shim stock at each end of the arbor. Position the If the number is positive, subtract that value from
bearing caps on the arbor tool. Install the attaching the thickness of the depth shim(s). I f the number is 0
bolts. Tighten the cap bolts to 14 N-m (10 ft. lbs.) no change is necessary.
torque. After selecting the proper pinion depth shim (s),
(5) Trial fit depth shim(s) between the crossbore remove the measurement tools from the axle hous
arbor and gauge block (Fig. 40). The depth shim(s) ing.
fit must be snug b u t not tight (drag f r i c t i o n of a
feeler gauge blade).
Depth shims are available i n 0.001-inch incre
ments from 0.020 i n c h to 0.038 inch.
Original Pinion Replacement Pinion Gear Depth Variance

Gear Depth
Variance -3 -1 i +1 +2 +3 +4
+4 + 0.008 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0
+3 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001
+2 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002
+1 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003
0 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004
-1 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005
-2 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006
-3 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007
-4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008

J8902-46
ADJUSTMENTS {Continued)
DIFFERENTIAL BEARING PRELOAD AND GEAR Measure the backlash at 4 positions (90 degrees
LASH apart) around the ring gear. Locate and mark the
area of minimum backlash.
BEARING PRELOAD AMD GEAR LASH (3) Rotate the ring gear to the position of the least
ADJUSTMENT backlash. Mark the gear so that all future backlash
The following must be considered when adjusting measurements will be taken with the same gear
bearing preload and gear backlash: teeth meshed.
• The maximum ring gear backlash variation is
0.003 inch (0.076 mm)
• Mark the gears so the same teeth are meshed
during all backlash measurements
• Maintain the torque while adjusting the bearing
preload and ring gear backlash
• Excessive adjuster torque will Introduce a high
bearing load and cause premature bearing failure.
Insufficient torque can cause excessive differential
case free-play and ring gear noise
• Insufficient adjuster torque will not support the
ring gear correctly. This can cause excessive differen
tial case free-play and ring gear noise.
The d i f f e r e n t i a l b e a r i n g cups w i l l n o t always
i m m e d i a t e l y follow the threaded a d j u s t e r s as
they are moved d u r i n g adjustment. Ensure
a c c u r a t e b e a r i n g c u p responses t o t h e a d j u s t Fig. 42 Ring Gear Backlash Measurement
ments. M a i n t a i n t h e gear teeth engaged
(meshed), as m a r k e d . T h e b e a r i n g s m u s t b e (4) Loosen the right-side, tighten the left-side
seated b y r a p i d l y r o t a t i n g t h e p i n i o n gear a threaded adjuster. Obtain backlash of 0.003 to 0.004
h a l f t u r n b a c k and f o r t h . D o t h i s f i v e t o t e n inch (0.076 to 0.102 mm) with each adjuster tight
times each t i m e t h e threaded adjusters are ened to 14 N-m (10 ft. lbs.) torque. Seat the bearing
adjusted. cups with the procedure described above.
(1) Use Wrench C-4164 to adjust each threaded (5) Tighten the differential bearing cap bolts to'
adjuster inward (Fig. 41). Adjust until the differen 136 N-m (100 ft. lbs.) torque.
tial bearing free-play Is eliminated. Allow some ring (6) Use Wrench C-4164 to tighten the right-side
gear backlash (approximately 0.01 inch/0.25 mm) threaded adjuster to 102 N-m (75 ft. lbs.) torque.
between the ring and pinion gear. Seat the bearing Seat the bearing cups with the procedure described
cups with the procedure described above. above. Continue to tighten the right-side adjuster
and seat bearing cups until the torque remains con
stant at 102 N-m (75 ft, lbs.)
(7) Measure the ring gear backlash. The range of
backlash is 0.006 to 0.008 inch (0.15 to 0.203 mm).
Continue increasing the torque at the right-side
threaded adjuster until the specified backlash is
obtained.
The left-side threaded adjuster torque should
have approximately 102 N«m (75 f t . lbs.) t o r q u e .
If t h e t o r q u e is c o n s i d e r a b l y less, t h e c o m p l e t e
adjustment procedure must be repeated.
(8) Tighten the left-side threaded adjuster until
102 N-m (75 ft. lbs.) torque is indicated. Seat the
bearing rollers with the procedure described above.
Do this until the torque remains constant.
(9) Install the threaded adjuster locks. Ensure the
lock finger is engaged with the adjuster hole. Tighten
Fig, 41 Threaded Adjuster Toot the lock screws to 10 N-m (90 in. lbs.) torque.
(2) Install Dial Indicator (Fig. 42). Position the
plunger against the drive side of a ring gear tooth.
ADJUSTMENTS {Continued)
GEAR CONTACT PATTERN (2) Rotate the ring gear one complete revolution in
The ring gear teeth contact patterns will show i f both directions.
the pinion gear depth shim(s) have the correct thick (3) Note patterns In compound. Refer to chart for
ness. It will also show i f the ring gear backlash has Interpretation of contact patterns and adjust accord
been adjusted correctly. The backlash must be main ingly.
tained within the specified limits until the correct (4) Install the axle shafts. Refer to Axle Shaft
teeth contact patterns are obtained. Installation within this group.
• Excessive backlash is corrected by moving the (5) Install the housing cover. Refill the differential
ring gear teeth closer to the pinion gear teeth with lubricant.
• Insufficient backlash is corrected by moving the (6) Install the RWAL/ABS brake speed sensor and
ring gear away from the pinion gear cover onto the axle housing. Tighten the sensor to 13
(1) Apply yellow ferrous (Iron) oxide compound to N-m (10 ft. lbs.) torque.
both drive and coast sides of ring gear teeth.
GEAR TEETH CONTACT PATTERNS
DRIVE SIDE COAST SIDE

O F RING O F RING
DESIRABLE CONTACT PATTERN.

PATTERN SHOULD BE CENTERED
HEEL TOE TOE HEEL
PATTERN SHOULD BE CENTERED O N
THE COAST SIDE O F T O O T H ,
THE T O E . THERE SHOULD ALWAYS
THE T O O T H .

SHIM REQUIRED.
RING GEAR BACKLASH CORRECT

SHIM REQUIRED.

CORRECT D E C R E A S E RING
GEAR BACKLASH.

CORRECT. I N C R E A S E RING
GEAR BACKLASH.
J9003-24
BR - DIFFERENTIAL AND DRIVELINE 3 - 75
SIDE GEAR CLEARANCE MEASUREMENT AND SIDE GEAR CLEARANCE 0.007

ADJUSTMENT THRUST WASHER THICKNESS + 0.033
TOTAL 0.040
When measuring side gear clearance, check each
gear Independently. I f i t necessary to replace a side I ^ ^ 0.040
REPLACEMENT WASHER THICKNESS "0.037
gear, replace both gears as a matched set. NEW SIDE GEAR CLEARANCE 0.003
(1) Install the axle shafts and C-clip locks and pin J9203-31
ion mate shaft. I f necessary, refer to the Installation
located within this group. Fig. 44 Side Gear Calcuiations
(2) Measure each side gear clearance. Insert a thickness and install the thrust washer. Assemble
matched pair of feeler gauge blades between the gear the differential case without the C-clip lock installed
and differential housing on opposite sides of the hub and measure the side gear clearance.
(Fig. 43). (6) Compare both clearance measurements. I f the
difference is less than 0.012 inch (0.305 mm), add
clearance recorded when the C-clip lock was installed
to thrust washer thickness measured. The sum will
determine the required thickness of the replacement
thrust washer.
(7) I f clearance is 0.012 inch (0.305 mm) or
greater, both side gears must be replaced (matched
set) and the clearance measurements repeated.
(8) I f clearance (above) continues to be 0.012 inch
(0.305 mm) or greater, the case must be replaced.
S P E C I F I C A T I O NIS
9 1/4 INCH AXLE
Fig. 48 Side Gear Ciearance Measurement Axle Type Semi-floating, hypoid

Lubricant SAE 80W-90
(3) I f side gear clearances Is no more than 0.005 Lube Capacity .2.3 L (4.8 pts.)
inch. Determine i f the shaft Is contacting the pinion
Axle Ratio 3.21, 3.55, 3.92
gear mate shaft. Do not remove the feeler
Differential
gauges, inspect the axle shaft w i t h the feeler
Case Clearance . 0.12 mm (0.005 in.)
gauge inserted behind the side gear. I f the end of
the axle shaft is not contacting the pinion gear mate Case Flange Runout . . . .0.076 mm (0.003 in.)
shaft, the side gear clearance Is acceptable. Ring gear
(4) I f clearance Is more than 0.005 inch (axle shaft Diameter .23.50 cm (9.25 in.)
not contacting mate shaft), record the side gear clear Backlash 0 12-0.20 mm (0.005-0.008 in.)
ance. Remove the thrust washer and measure its Runout . . . .0.127 mm (0.005 in.)
thickness with a micrometer. Add the washer thick Pinion Bearing
ness to the recorded side gear clearance. The sum of Preload 1-2 N-m (10-20 in.lbs.)
gear clearance and washer thickness will determine TORQUE
required thickness of replacement thrust washer
(Fig. 44).
DESCRIPTION TORQUE
In some cases, the end of the axle shaft will move Bolt, Diff. cover. . . . . . 47 N-m (35 ft. lbs.)
and contact the mate shaft when, the feeler gauge is
Bolt, Bearing cap , . 136 N-m (100 ft. lbs.)
inserted. The C-clip lock is preventing the side gear
Nut, Pinion 285 N-m (210 ft. lbs.)
from sliding on the axle shaft.
Bolt, Ring gear . . . . . . 95 N-m (70 ft. lbs.)
(5) I f there Is no side gear clearance, remove the
C-clip lock from the axle shaft. Use a micrometer to Bolt, Backing plate . . . . . .64 N-m (48 ft. lbs.)
measure the thrust washer thickness. Record the Bolt, RWAL/ABS sensor 24 N-m (18. ft. lbs.)
Installer—C-3980A
BR • DIFFERENTIAL AND DRIVELINE 3 -
Remover/Installer, Bearing Set—C-4306

Wrench—6719 Fixture Tool—6965

jgg DIFFERENTIAL AND DRIVELINE 3 - 79
MODEL 60/70/80 AXLES
INDEX
page page
GENERAL INFORMATION DIFFERENTIAL 91

GENERAL INFORMATION 79 EXCITER AND RING GEAR . 94
LUBRICANT 81 PINION GEAR 95
DESCRIPTION AND OPERATION PINION SEAL—MODEL 70/80 90
STANDARD DIFFERENTIAL OPERATION 81 PINION SHAFT SEAL 89
TRAC-LOK/POWER-LOK OPERATION 81 DISASSEMBLY AND ASSEMBLY
DIAGNOSIS AND TESTING POWER-LOK—MODEL 70/TRAC-LOK—
DRIVELINE SNAP 83 MODEL 80 104
GEAR AND BEARING NOISE 83 STANDARD DIFFERENTIAL 99
GENERAL INFORMATION 82 TRAC-LOK DIFFERENTIAL 100
LIMITED SLIP DIFFERENTIAL 84 CLEANING AND INSPECTION
LOW SPEED KNOCK 83 AXLE COMPONENTS 107
REAR AXLE ALIGNMENT 83 TRAC-LOK AND POWER-LOK 107
SERVICE DIAGNOSIS 85 ADJUSTMENTS
TRAC-LOK NOISE DIAGNOSIS 87 DIFFERENTIAL BEARING PRELOAD AND
VIBRATION 83 GEAR LASH 110
SERVICE PROCEDURES PINION GEAR DEPTH 108
DRAIN AND REFILL 87 SPECIFICATIONS
WHEEL BEARINGS 88 MODEL 60/70/80 REAR AXLES 113
REMOVAL AND INSTALLATION TORQUE 113
AXLE ASSEMBLY 88 SPECIAL TOOLS
AXLE ASSEMBLY 91 MODEL 60/70/80 AXLES 114
DIFFERENTIAL SIDE BEARINGS 92
GENERAL INFORMATION side. The tubes are pressed in to form a one-piece

axle housing.
GENERAL INFORMATION
The axle housing (Fig. 1) consists of an iron center
casting with axle shaft tubes extending from either
3-80 differential and driveline WASHER COVER
General Information (continued)
SIDE GEAR GASKET

OR
SEALER
WASHER
EXCITOR
RING
CONE
FLANGE
A N D AXLE
SHAFT
OIL SEAL > X

GASKET WASHER
BOLT J9203-54
Fig. 1 Model 60, 70 and 80 Rear Axle 09

3B
GENERAL I N F O R M A T I O N (Continued)
The integral type housing, hypoid gear design has In operation, power flow occurs as follows:
the centerline of the pinion set below the centerline • The pinion gear rotates the ring gear
of the ring gear. • The ring gear (bolted to the differential case)
The axles are equipped with full floating axle rotates the case
shafts. Vehicle load is supported by the axle housing • The differential pinion gears (mounted on the
tubes. The full-float axle shafts are retained by bolts pinion mate shaft in the case) rotate the side gears
attached to the hub. The hub rides on two taper • The side gears 'splined to the axle shafts) rotate
bearings at the outboard end of the axle tube. The the shafts
axle shafts can be removed without disassembling During straight- ahead driving, the differential
the wheel bearings. The wheel bearings are opposed pinion gears do not rotate on the pinion mate shaft.
tapered roller bearings that contained in the wheel This occurs because input torque applied to the gears
hub. is divided and distributed equally between the two
The removable steel cover provides a means for side gears. As a result, the pinion gears revolve with
inspection and service without removing the axle the pinion mate shaft but do not rotate around i t
from the vehicle. (Fig. 2).
A stamped metal axle gear ratio identification tag IN STRAIGHT A H E A D DRIVING
is attached to the housing cover with one cover bolts. EACH W H E E L ROTATES AT 100%
This tag also identifies the number of ring and pinion O F CASE SPEED
teeth. An addition tag will be attached i f equipped
with a limited-slip differential.
The differential case is a one-piece design. The dif
ferential pinion mate shaft is retained with a roll
pin. Model 60 axles with the optional Trac-lok use a
one piece case. Model 70 axles with the optional Pow-
er-Lok use a two piece differential case. Model 80
axles with the optional Trac-lok also uses a two piece
case. Differential bearing preload and ring gear back
lash are adjusted with shims located between the dif
ferential bearing cones and case.
4__P PINION G E A R S ROTATE M V
For complete drive axle assembly removal WITH C A S E J9303-13
and installation refer to Drive Axle Assembly
Replacement in this Group. Fig, 2 Differential Operation—Straight Ahead Driving
When turning corners, the outside wheel must
LUBRICANT travel a greater distance than the inside wheel i n
Dana® axles use a thermally stable Lubricant, order to complete a turn. The difference must be
80W-90 or equivalent GL-5 grade lubricant. Vehicles compensated for, to prevent the tires from scuffing
with Trac-Lok/Power-Lok also use 6 oz. of friction and skidding through turns. To accomplish this, the
modifier added to the lubricant. Dana 80 4x4 vehicles differential allows the axle shafts to turn at unequal
use 10 oz. of friction modifier added to the lubricant. speeds (Fig. 3). I n this instance, the input torque
applied to the pinion gears is not divided equally.
CAUTION: If axle is submerged in water, lubricant
The pinion gears now rotate around the pinion mate
must be replaced immediately to avoid possible
shaft in opposite directions. This allows the side gear
premature axle failure.
and axle shaft attached to the outside wheel to rotate
at a faster speed.
DESCRIPTION AND OPERATION TRAC-LOK/POWER-LOK OPERATION

Trac-Lok differential is available on Model 60 and
STANDARD DIFFERENTIAL OPERATION 80 axles. Power-Lok differential is available on Model
The differential gear system divides the torque 70 axles.
between the axle shafts. I t allows the axle shafts to In a conventional differential, torque applied to the
rotate at different speeds when turning corners. ring gear is transmitted to the axle shafts through
Each differential side gear is splined to an axle differential gears. During normal operation, the
shaft. The pinion gears are mounted on a pinion torque transmitted to each wheel is equal at all
mate shaft and are free to rotate on the shaft.. The times. However, i f one wheel spins, the opposite
pinion gear is fitted in a bore in the differential case wheel will generate only as much torque as the spin
and is positioned at a right angle to the axle shafts. ning wheel.
D E S C R I P T I O N AND O P E R A T I O N (Continued)
j AXLE % J
OUTER W H E E L 100% DIFFERENTIAL INNER W H E E L

110% CASE SPEED C A S E SPEED 9 0 % CASE SPEED
P I N I O N GEARS ROTATE
O N P I N I O N SHAFT J9303-14
Fig. 3 Differential Operation—On Turns

In the Trac-Lok/Power-Lok differential, part of the
ring gear torque is transmitted through clutch packs.
The clutch packs contain multiple disc clutches, that
have radial grooves on the plates and concentric
grooves on the discs.
Trac-Lok differentials can also use plates and discs
with bonded fiber material that is smooth in appear
ance.
In operation, the Trac-Lok/Power-Lok clutches are
engaged by two concurrent forces. The first being
preload force exerted through dished spring washers
contained In the clutch packs. The second from sepa Fig. 4 Limited Slip Differential Operation—Both
rating forces generated by the side gears as torque is Wheels Driving
applied through the ring gear (Fig. 4).
air. This will overheat them and brinell the
The Trac-Lok design provides differential action
bearing surfaces. This will result in noisy oper
needed for' turning corners and for driving straight
ation after repair.
ahead. However, when one wheel looses traction, the
Axle gear problem conditions are usually the result
clutch packs transfer additional torque to the wheel
of:
having the most traction. Trac-Lok differentials resist
• Insufficient lubrication
wheel spin on bumpy roads and provide more pulling
• Incorrect or contaminated lubricant
power when one wheel looses traction. Pulling power
• Overloading (excessive engine torque) or exceed
is provided continuously until both wheels loose trac
ing vehicle weight capacity
tion. I f both wheels slip due to unequal traction,
• Incorrect clearance or backlash adjustment
Trac-Lok operation is normal. I n extreme cases of dif
Insufficient lubrication is usually the result of a
ferences of traction, the wheel with the least traction
housing cover leak. I t can also be from worn axle
may spin.
shaft or pinion gear seals. Check for cracks or porous
areas in the housing or tubes.
DIAGNOSIS AND TESTING Using the wrong lubricant will cause overheating
and gear failure. Gear tooth cracking and bearing
GENERAL INFORMATION spalling are indicators of this.
Axle bearing problem conditions are usually caused Axle component breakage is most often the result
by: of:
• Insufficient or incorrect lubricant © Severe overloading
• Foreign matter/water contamination • Insufficient lubricant
• Incorrect bearing preload torque adjustment • Incorrect lubricant
• Incorrect backlash (to tight) • Improperly tightened components
When serviced, the bearings must be cleaned thor Overloading occurs when towing heavier than rec
oughly. They should be dried with lint-free shop tow ommended loads. Component breakage can occur
els. Never spin d r y bearings w i t h compressed when the wheels are spun excessively. Incorrect
DIAGNOSIS AND TESTING {Continued)

lubricant quantity contributes to breakage. Loose dif This will load the bearings and change the noise
ferential components can also cause breakage. level. Where axle bearing damage is slight, the noise
Incorrect bearing preload or gear backlash will not is usually not noticeable at speeds above 30 mph.
result in component breakage. Mis-adjustment will
produce enough noise to cause service repair before a LOW SPEED KNOCK
failure occurs. I f a mis-adjustment condition Is not Low speed knock is generally caused by a worn
corrected, component failure can result. U-joint or by worn side-gear thrust washers. A worn
Excessive bearing preload may not be noisy. This pinion gear shaft bore will also cause low speed
condition will cause high temperature which can knock.
result in bearing failure.
VIBRATION
GEAR AND BEARING NOISE Vibration at the rear of the vehicle is usually
caused by a:
GEAR NOISE • Damaged drive shaft
Axle gear noise can be caused by insufficient lubri • Missing drive shaft balance weight
cant. Incorrect backlash, tooth contact, or worn/dam • Worn, out-of-balance wheels
aged gears can cause noise. • Loose wheel lug nuts
Gear noise usually happens at a specific speed © Worn U-joint
range. The range is 30 to 40 mph, or above 50 mph. • Loose spring U-bolts
The noise can also occur during a specific type of • Loose/broken springs
driving condition. These conditions are acceleration, ® Damaged axle shaft bearings
deceleration, coast, or constant load. • Loose pinion gear nut
When road testing, accelerate the vehicle to the © Excessive pinion yoke run out
speed range where the noise is the greatest. Shift • Bent axle shaft
out-of-gear and coast through the peak-noise range. Check for loose or damaged front-end components
I f the noise stops or changes greatly, check for insuf or engine/transmission mounts. These components
ficient lubricant. Incorrect ring gear backlash, or can contribute to what appears to be a rear-end
gear damage can cause noise changes. vibration. Do not overlook engine accessories, brack
Differential side and pinion gears can be checked ets and drive belts.
by turning the vehicle. They usually do not cause All driveline components should be examined
noise in straight-ahead driving. These gears are before starting any repair.
loaded during vehicle turns. I f noise does occur dur Refer to Group 22, Wheels and Tires for additional
ing vehicle turns, the side or pinion gears could be information.
worn or damaged. A worn pinion gear mate shaft can
also cause a snapping or a knocking noise. DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted
BEARING NOISE into gear (or the clutch engaged), can be caused by:
The axle shaft, differential and pinion gear bear • High engine idle speed
ings can all produce noise when worn or damaged. • Loose engine/transmission/transfer case mounts
Bearing noise can be either a whining, or a growling • Worn U-joints
sound. • Loose spring mounts
Pinion gear bearings have a constant-pitch noise. • Loose pinion gear nut and yoke
This noise changes only with vehicle speed. Pinion • Excessive ring gear backlash
bearing noise will be higher because it rotates at a • Excessive side gear/case clearance
faster rate. Drive the vehicle and load the differen The source of a snap or a clunk noise can be deter
tial. I f bearing noise occurs the pinion rear bearing is mined with the assistance of a helper. Raise the vehi
the source of the noise. I f the bearing noise is heard cle on a hoist with the wheels free to rotate. Instruct
during a coast, front bearing is the source. the helper to shift the transmission into gear. Listen
Worn, damaged differential bearings usually pro for the noise, a mechanics stethoscope is helpful i n
duce a low pitch noise. Differential bearing noise is isolating the source of a noise.
similar to pinion bearing. The pitch of differential
bearing noise is also constant and varies only with REAR AXLE ALIGNMENT
vehicle speed.
Axle shaft bearings produce noise and vibration MEASUREMENT
when worn or damaged. The noise generally changes The following procedure can be used to determine
when the bearings are loaded. Road test the vehicle. if abnormal rear tire tread wear is the result of a
Turn the vehicle sharply to the left and to the right. bent or deformed rear axle shaft.
DIAGNOSIS AND TESTING (Continued)

(1) Raise both rear wheels off the surface with a I f the BTR distance measurement is less than the
frame contact hoist. average FTR and RTR distance measurement, the
(2) Attach a one-Inch long piece of masking tape camber will be positive ( + ). I f the BTR distance
at the center of each tire tread for use as reference measurement is greater than the average FTR and
marks. RTR distance, the camber will be negative ( - ).
(3) Rotate the rear wheels until both reference I f the toe position or camber is not acceptable, a
marks face the front of the vehicle. Measure the dis bent or deformed rear axle shaft Is most likely the
tance between the outside edges of the two pieces of cause.
tape. Record this measurement as the Front Of Tire
(FTR) measurement. LIMITED SLIP DIFFERENTIAL
(4) Rotate the rear wheels until both reference Under normal traction conditions, engine torque is
marks face the rear of the vehicle. Measure the dis divided evenly. With low-traction surfaces, engine
tance between the outside edges of the two pieces of torque Is transferred to the wheel with the most tire
tape. Record this measurement as the Rear Of Tire traction. When diagnosing a limited-slip differential
(RTR) measurement. the wheel with the least traction can continue spin
(5) Subtract the RTR measurement from the FTR ning.
measurement to obtain the amount of wheel toe. The The most common problem is a chatter noise when
acceptable rear wheel toe-in position is 1/16 in. (1.6 turning corners. Check for incorrect or contaminated
mm) to 3/16 in. (4.8 mm) toe-out. lubricant. Replace the gear lubricant If necessary.
(6) Rotate the rear wheels until the reference • With Trac-Lok® differentials add a container of
marks are facing downward. Measure the distance Mopar Trac-Lok Lubricant.
between the outside edges of the two pieces of tape. This will correct the condition i n most Instances. I f
Record this measurement as the Bottom Of Tire the chatter persists, clutch damage could have
(BTR) measurement. occurred.
(7) Average the FTR and the RTR distance mea After changing the lubricant, drive the vehicle and
surements. Subtract the BTR measurement from this make 10 to 12 slow, figure-eight turns. This maneu
average distance to obtain the camber. The accept ver will pump lubricant through the clutches.
able amount of camber is 1/16 inch to 3/32 inch (1.6
to 2.4 mm).
NOTE: FTR + RTR Divided By two Minus BTR

Equals Camber
BR DIFFERENTIAL AND DRIVELINE 3 • 85
SERVICE DIAGNOSIS SERVICE DIAGNOSIS
CONDITION P O S S I B L E CAUSES CORRECTION

bearings.
4. Excessive gear backlash 4. Check adjustment of ring gear backlash and pinion gear.
gear.
6. Loose drive pinion gearshaft 6. Tighten drive pinion gearshaft yoke nut with specified torque.
yoke nut.
adjustment.
surfaces.
alignment.
4. Grabbing clutch. 4. Replace broken axle shaft. Inspect clutch and make necessary
DIFFERENTIAL C A S E 1. Improper adjustment of Replace cracked case; examine gears and bearings for possible
Replace cracked case; examine gears and bearings for possible
Replace cracked case; examine gears and bearings for possible
Replace cracked case. After inspecting for other possible
DIFFERENTIAL G E A R S Insufficient lubrication. . Replace scored gears. Scoring marks on the drive face of gear
2. Improper grade of lubricant. . Replace scored gears. Inspect all gears and bearings for
3. Excessive spinning of one . Replace scored gears. Inspect all gears, pinion bores and shaft
LOSS O F LUBRICANT Lubricant level too high. Drain excess lubricant by removing fill plug and allow lubricant
J9503-3
SERVICE DIAGNOSIS (CONT'D)
LOSS O F LUBRICANT 2. Worn axle shaft seals. 2. Replace worn seals.

4 Worn drive pinion gear shaft 4. Replace worn drive pinion gear shaft seal.
seal.
AXLE OVERHEATING 1. Lubricant level too low. 1. Refill differential housing.

lubricant. j
necessary.
scoring.
GEAR TEETH BROKE 1. Overloading. 1. Replace gears. Examine other gears and bearings for possible j
(RING GEAR A N D P I N I O N ) damage.
2. Erratic clutch operation. 2. Replace gears and examine the remaining parts for possible
damage. Avoid erratic clutch operation.
AXLE NOISE 1. Insufficient lubricant. 1. Refill axle with correct amount of the proper lubricant.
bearings.
8 . Loose differential bearing cap 8 . Tighten with specified torque
bolts
J9503-4

TRAC-LOK NOISE DIAGNOSIS
If a noise occurs when turning corners, the most
probable cause is incorrect or contaminated lubri
cant. Before removing the Trac-lok unit for repair,
drain, flush and refill the axle with the specified
lubricant. Refer to Lubricant change i n this Group.
A container of Trac-lok Lubricant (friction modifier)
should be added after repair service or a lubricant
SPECIAL
change.
TOOL -
Vehicles with a limited slip differential should be 6790
road tested by making 10 to 12 slow figure eight
turns. This maneuver will pump the lubricant
through the clutch discs to eliminate a possible chat
ter or pop noise complaint.
Refer to Group 0, Lubrication and Maintenance for J9403-51
additional information. Fig. 5 Trac-loc Test

DIFFERENTIAL TEST (4) Remove the differential housing cover and
drain lubricant from the housing and axle shaft
WARNING: WHEN SERVICING VEHICLES WITH A tubes.
LIMITED SLIP DIFFERENTIAL DO NOT USE THE (5) With standard differential, clean the differen
ENGINE TO TURN THE AXLE AND WHEELS. BOTH tial and the housing cavity with a flushing oil (or
REAR WHEELS MUST BE RAISED AND THE VEHI light engine oil). This will remove the residual lubri
CLE SUPPORTED. A LIMITED SLIP AXLE CAN cant and foreign matter.Do not use water, steam,
EXERT ENOUGH FORCE (IF ONE WHEEL IS IN kerosene or gasoline for flushing.
CONTACT WITH THE SURFACE) TO CAUSE THE (6) Scrape the residual sealant from the housing
VEHICLE TO MOVE. and cover mating surfaces. Clean the mating surfaces
with mineral spirits. Apply a bead of MOPAR Sili
The differential can be tested without removing the
cone Rubber Sealant on the housing cover (Fig. 6).
differential case by measuring rotating torque. Make
Allow the sealant to cure for a few minutes.
sure brakes are not dragging during this measure
ment. SEALING CONTOUR OF BEAD
(1) Engine off, transmission in neutral, and park
ing brake off.
(2) Place blocks in front and rear of both front
wheels.
(3) Raise one rear wheel until i t is completely off
the ground.
(4) Remove wheel and bolt Special Tool 6790 to
studs.
(5) Use torque wrench on special tool to rotate
wheel and read rotating torque (Fig. 5).
(6) I f rotating torque is less than 22 N-m (30 ft.
lbs.) or more than 271 N-m (200 ft. lbs.) on either
wheel the unit should be service.
SERVICE PROCEDURES
DRAIN AND REFILL

(1) Drive the vehicle until the gear lubricant
reaches normal operating temperature.
(3) Remove the lubricant fill hole plug from the Fig. 6 Typical Housing Cover
differential housing cover.
NOTE: Install the housing cover within 5 minutes
after applying the sealant. Sf not installed, the seal
ant must be removed and another bead applied.
3 - 88 DIFFERENTIAL AND DRIVELINE — — BR

(7) Install the cover on the differential. Install the (10) Tap the locking wedge into the spindle key-
identification tag. Tighten the cover bolts to 47 N-m way and adjustment nut.
(35 ft. lbs.). (11) Install the axle shaft.
CAUTION: Overfilling the differential can result in

lubricant foaming and overheating. REMOVAL AND INSTALLATION
(8) Refill the differential with the specified quan AXLE ASSEMBLY
tity of Mopar Hypoid gear Lubricant. With Trac-Lok
differentials, add a container of friction modifier. REMOVAL
(9) Install the fill hole plug. It is not necessary to remove the complete axle
(10) Road test the vehicle. from the vehicle for routine differential service. I f the
differential housing or axle shaft tubes are damaged,
WHEEL BEARINGS the complete axle assemble can be removed.
(1) Raise vehicle and place support stands axle.
REMOVAL (2) Use a wooden block to retain the brake pedal
(1) Remove the axle shaft. in the up position.
(2) Remove the lock wedge and adjustment nut. (3) Remove axle shafts, wheels, hubs and brake
(3) Remove the hub and drum assembly. The outer drums.
wheel bearing will slide out as the hub is being (4) Disconnect brake lines and cap the fittings to
removed. prevent loss of brake fluid.
(4) Remove inner grease seal and discard. (5) Disconnect parking brake cables and cable
(5) Remove inner wheel bearing an inspect wheel brackets.
bearings for wear. Replace as necessary. (6) Remove RWAL sensor from axle housing.
(7) Scribe alignment reference marks on
INSTALLATION drive shaft U-joint and pinion yoke.Disconnect
(1) Thoroughly clean both wheel bearings and inte the drive shaft U-joint from the pinion yoke. Secure
rior of the hub with an appropriate cleaning solvent. it in an upright position to prevent damage to the
(2) I f a bearing and cup must be replaced, remove U-joint.
the cup from the hub bore. Use a brass drift or an (8) Remove the rear shock absorbers and the rear
appropriate removal tool to tap out the cup. spring U-bolts from the axle.
(3) Install the replacement bearing cup(s) with an (9) Remove the rear axle from the vehicle.
appropriate installation tool.
(4) Apply lubricant to surface area of the hub bore. INSTALLATION
Install the inner wheel bearing in the hub. Install a (1) I f the differential housing cover was removed,
replacement bearing seal with an appropriate seal ensure differential housing and cover mating sur
installation tool. faces are clean.
(5) Inspect the bearing and seal contact surfaces (2) I f cover was removed, apply a bead of MOPAR
on the axle tube spindle for burrs and/or roughness. Silicone Rubber Sealant around the cover bolt circle.
(6) Remove all the rough contact surfaces from the Install the differential housing cover. Tighten the
axle. Apply a coating of multi-purpose NLGI, grade 2, cover bolts to 47 N-m (35 ft. lbs.). Install the axle
EP-type lubricant to the axle. gear ratio identification tag under one of the cover
bolts.
CAUTION: Use care to prevent the inner wheel (3) Position axle under the rear springs.
bearing and bearing seal from contacting the axle (4) Install the spring U-bolts and tighten the nuts
tube spindle threads during installation. Otherwise, to the specified torque.
the threads, bearing, and seal could be damaged. (5) Install shock absorbers.
(6) Connect parking brake cables and cable brack
(7) Carefully slide the hub onto the axle. Install ets.
the outer wheel bearing, the locktab and outer wheel (7) Install RWAL sensor.
bearing locknut. (8) Connect the brake lines. Install the hubs and
(8) Tighten the adjustment nut to 163-190 N-m brake drums. Adjust the wheel bearings (refer to
(120-140 ft. lbs.) while rotating the wheel. Wheel Bearing Adjustment).
(9) Loosen the adjustment nut 1/8 of-a-turn (120 (9) Remove the block from the brake pedal. Bleed
degrees) to provide 0.001-inch to 0.010-inch wheel and adjust the brakes.
bearing end play.
REMOVAL AMD INSTALLATION (Continued)

(10) Connect the drive shaft to the pinion yoke PINION SEAL
with the reference marks aligned. Tighten the U-joint
clamp bolts to 21 N-m (16 ft. lbs.).
(12) Remove the fill hole plug from housing cover.
Fill the housing to the correct level with MOPAR
Hypoid gear Lubricant. I f equipped with Trac-Lok
add correct amount of friction modifier.
(18) Install the fill hole plug. Remove the supports
and lower the vehicle.
PINION SHAFT SEAL
REMOVAL
(2) Mark the U-joint, pinion yoke, and pinion shaft
for reference.
(4) Remove the pinion yoke nut and washer. Use J9203-55
Remover C-452 and Wrench C-3281 to remove the Fig. 8 Pinion Seal Removal
pinion yoke (Fig. 7). (4) Verify that the pinion rotation resistance value
(5) Using an inch pound torque wrench, check is equal to that recorded during removal procedure.
rotation resistance of the pinion and record the If not, adjust flange nut until pinion resistance is cor
results to aid installation. rect.
for installation alignment reference. DIFFERENTIAL
C-452 J9102-31
(7) Use Remover C-748 to remove the pinion gear
seal (Fig. 8).
INSTALLATION
(1) Apply a light coating of gear lubricant on the Fig. 9 Tightening Pinion Shaft Nut
lip of pinion seal. Install the new seal with Installer (5) Align the installation reference marks and
C-3719-A and Handle C-4735. attach the drive shaft to the yoke.
(2) Align the installation reference marks and (6) Add hypoid gear lubricant to the differential
position the yoke on the pinion gear. housing, i f necessary.
(3) Install the pinion yoke, washer, and nut on shaft. (7) Lower the vehicle.
Tighten the nut to 292 N-m (215 ft. lbs.) (Fig. 9).
3 - Si DIFFERENTIAL AND DRIVELINE BR

PINION SEAL—MODEL 70/80 . (2) Align the installation reference marks and
position the yoke on the pinion gear.
REMOVAL (3) Install yoke with Installer D-191 (Fig. 12).
(2) Mark the U-joint, pinion yoke, and pinion shaft YOKE
for reference.
for installation alignment reference.
J9402-61
Fig. 12 Yoke Installation

(4) Install washer with concave surface against
yoke on Model 70 axle. Install nut on shaft and
C-452 J9102-31
tighten nut to (Fig. 13);
• Model 70: 298-379 N-m (220-280 ft. lbs.) torque
Fig. 10 Pinion Yoke Removal • Model 80: 597-678 N-m (440-500 ft. lbs.) torque
(6) Use Remover 7794A and slide hammer to
DIFFERENTIAL
remove pinion seal (Fig. 11).
SPECIAL TOOL
7794A
PINION SEAL
J9402-59X
Fig. 11 Pinion Seal Removal

INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal. Install the new seal with Installer
D-187B. Fig. 13 Tightening Pinion Shaft Nut
HEHOWAL AND INSTALLATION (Gontinued)

Optional Torque Method, Model 80: Torque pin (9) Remove the shock absorber lower attaching
ion nut to 339 N-m (250 ft. lbs.). Then scribe a line nuts and bolts.
on the yoke 3/8 of an inch from one point of the pin (10) Support axle and remove rear spring U-bolts
ion nut (Fig. 14). Tighten the nut until the point of and the spring brackets.
the nut lines up with the scribe mark. This will
tighten the nut to the correct torque. WARNING: AXLE MAY ROTATE ON ' SUPPORT
WHEN SPRING CLAMP BOLTS ARE REMOVED
ENSURE A1LE IS SECURED ON SUPPORT
(11) Remove the axle assembly from the vehicle.

(12) Wash and clean the outer surface of the hous
ing and tubes. Use an appropriate cleaning solution
and dry the surface with compressed air.
INSTALLATION
(1) Position the rear axle spring pads over the
spring center bolts.
(2) Install the spring clamp bolts and nuts, and
shock absorber lower bolts. Tighten the nuts to the
specified torque.
(3) Connect the parking brake cables.
(4) Connect the brake fluid tube fittings to the
wheel cylinders. Bleed and adjust brakes refer to
Fig. 14 Pinion Nut Group 5 Brakes for procedure.
(5) Align the installation reference marks and (5) Align the installation reference marks and con
attach the drive shaft to the yoke. nect the drive shaft yoke to the pinion yoke. Tighten
(6) Add gear lubricant to the differential housing if the U-joint clamp bolts to 19-23 N-m (170-200 in.
necessary. lbs.) torque.
(7) Remove support and lower the vehicle. (6) Install wheel and tire assemblies.
AXLE ASSEMBLY
It is not necessary to remove the complete axle DIFFERENTIAL
from the vehicle for routine differential inspection
REMOVAL
and service. I f the differential housing, case or axle
shaft tubes are damaged the complete axle can be To service the differential the axle shafts must be
removed and replaced. removed. Refer to the removal procedures in this Group.
(1) Note the installation reference letters stamped
REMOVAL on the bearing caps and housing machined sealing
(1) Raise and support vehicle. surface (Fig. 15).
(2) Block the brake pedal i n the up (non-de
pressed) position with a wooden block.
(3) Remove the rear wheels and brake drums.
(4) Disconnect the brake fluid tube fittings from
the wheel cylinders. Cap the fittings to prevent loss
of brake fluid.
(5) Remove the vent hose from the brake tee nip
ple.
(6) Remove the brake tee bolt. Carefully detach
the brake fluid tubes from the clips.
(7) Disconnect the parking brake cables and unbolt
backing plates.
Mark the U-joint, pinion yoke, and pinion
shaft for reference.
prevent damage to the rear U-joint. Fig. 15 Bearing Cap Identification

(2) Remove the differential bearing caps. DIFFERENTIAL PRY BAR
pins seated i n the locating holes (Fig. 16). Install the
finger-tight.
Fig. 17 Differential Removal

CAUTION: Do not spread over 0.38 mm (0.015 in). If
Fig. 16 Spread Differential Housing the housing is over-separated, it could be distorted
or damaged.
ential housing. Attach Dial Indicator to housing pilot (3) Separate the housing enough to install the case
stud. Load the indicator plunger against the opposite in the housing. Measure the distance with the dial
side of the housing (Fig. 16) and zero the indicator. indicator (Fig. 16).
(4) Remove the dial indicator.
CAUTION: Do not spread over 0.38 mm (0.015 in), if
the housing is over-separated, it could be distorted (5) Install differential and outboard shim/spacer
or damaged. (selected thickness) in housing.
(6) Install case in the housing. Tap the differential
(5) Separate the housing enough to remove the case to ensure the bearings are fully seated (Fig. 18).
case from the housing. Measure the distance with the Remove the spreader.
dial indicator (Fig. 16). (7) Install the bearing caps at their original loca
(6) Remove the dial indicator. tions (Fig. 19). Tighten the bearing cap bolts to 77
(7) Pry the differential case loose from the hous N-m (57 ft. lbs.) torque.
ing. To prevent damage, pivot on housing with the
end of the pry bar against spreader (Fig. 17). DIFFERENTIAL SIDE BEARINGS
(8) Remove the case from housing. Mark or tag
REMOVAL
bearing cups and outboard shim/spacer (selected
thickness) indicating which side they were removed. (1) Remove Differential case from axle housing.
(2) Remove the bearings from the differential case
DIFFERENTIAL INSTALLATION with Press 938, and Adapter 1130 (Fig. 20).
DIFFERENTIAL SIDE BEARING INSTALLATION
pins seated in the locating holes (Fig. 16). Install the
If ring and pinion gears have been replaced, verify
differential side bearing preload and gear mesh back
finger-tight.
lash.
(1) Using tool C-4340 with handle C-4171, install
differential side bearings (Fig. 21).
(2) Install differential in axle housing.
Fig. 21 Install Differential Side Bearings


EXCITER AND RING GEAR EXCITER AMD RING GEAR INSTALLATION
(1) I f exciter ring was removed, align exciter ring
REMOVAL tab with slot in differential case (Fig. 24).
(1) Remove the differential case from axle housing.
(2) Clamp the differential case in a vise equipped
with soft jaws.
(3) Remove and discard the ring gear bolts.
(4) Tap the ring gear off with a rawhide or plastic
mallet (Fig. 22).
Fig. 24 Exciter Ring Alignment

(2) Invert the differential case and start two ring
gear bolts. This will provide case to ring gear bolt
Fig. 22 Ring Gear Removal hole alignment.
(5) The can be removed with a soft-faced hammer (3) Press the exciter ring onto the differential case
(Fig. 23). Discard exciter ring after removal. using the ring gear as a pilot (Fig. 25).
SLOT 8903-36
Fig. 25 Ring Gear Bolt Hole Alignment

(4) Install new ring gear bolts and alternately
Fig. 23 Exciter Ring Removal tighten to;
• Model 60 and 70: 163-190 N-m (120-140 ft. lbs.)
torque
• Model 80: 272-325 N-m (200-240 ft. lbs.) torque
BR DIFFERENTIAL AND DRIWELINE 3 - Ii

PINION IEAR (6) Remove the front pinion bearing cup and seal
with Remover C-4307 for model 80 or D-158 for
REMOVAL model 60/70 and Handle C-4171 (Fig. 28).
(1) Remove differential assembly from axle hous
ing.
HANDLE
REMOVER' J9302-22

Fig. 28 Front Bearing Cup Removal
(3) Remove the pinion gear from housing (Fig. 27).
Catch the pinion with your hand to prevent i t from (7) Remove the rear bearing cup from housing
falling and being damaged. (Fig. 29). Use Remover D-159 for model 80 or D-162
for model 60/70 and Handle C-4171.
RAWHIDE
HAMMER
DRIVER
HANDLE
J9302-25 J9302-23
Fig. 27 Remove Pinion Gear Fig. 29 Rear Bearing Cup Removal
(4) Remove the pinion gear seal with a slide ham

mer or pry out with bar.
(5) Remove oil slinger, front bearing.
PINION WASHER
Fig, 30 Pinion Preload Shims—Model 70/80

(8) Remove the preload shims on model 70/80 (Fig. (10) Remove the depth shims from the pinion gear
30) or collapsible spacer on model 60 axles (Fig. 31). shaft. Record the thickness of the depth shims.
(9) Remove the inner bearing from the pinion with
Splitter 1130 and Bridge 938 (Fig. 32).
Fig, 31 Collapsible Preload Spacer—Model 60 Fig, 82 inner Bearing Removal

BR DIFFERENTIAL AND DR1WEL1NE 3 -17
PINION GEAR INSTALLATION INSTALLER HANDLE
After selecting the proper pinion depth shim using
the Pinion Depth Measurement paragraph in the
Adjustment section of this Group, proceed with
installation procedure. Model 60 axle uses a collaps
ible spacer to preload the pinion bearings. Model
70/80 uses shims to set pinion bearing preload.
(1) On model 70/80 axles, place pinion depth shims
in axle housing rear bearing bore.
(2) Install the pinion rear bearing cup with
Installer C-4204 for model 80 or D - l l l for model
60/70 and Driver Handle C-4171 (Fig. 33). Ensure
cup is correctly seated.
INSTALLER
J9402-65
Fig. 34 Pinion Front Bearing Cup Installation
1
fa
HANDLE
INSTALLER
HANDLE 19402-66
Fig. 33 Pinion Rear Bearing Cup installation

(3) Install the pinion front bearing cup with
J9502-1
Installer C-4308 for model 80 or C-4203 for model
60/70 and Handle C-4171 (Fig. 34).
(4) I f equipped, install pinion front bearing, oil
slinger. (6) On model 60 axle, place the proper thickness
(5) Apply a light coating of gear lubricant on the depth shim on the pinion gear and install the rear
lip of pinion seal. Install seal with Installer D-163 bearing. Refer to Pinion Gear Depth paragraph i n
and Handle C-4171 (Fig. 35). Adjustments section of this group.
(7) Install the rear bearing (and slinger i f used) on
NOTE: Pinion depth shims are used to achieve the pinion gear with Installer D-389 for model 70/80
proper ring and pinion gear mesh. If the factory or C-3095A for model 60 and an arbor press (Fig. 36).
installed ring and pinion gears are reused, the pin (8) On model 60 axle, install a new collapsible pre
ion depth shim should not require replacement. load spacer on pinion shaft and install pinion gear in
Refer to Pinion Gear Depth paragraph in this sec housing (Fig. 37). On model 70/80 axles, install pin
tion to select the proper thickness shim before ion bearing preload shims (Fig. 38).
installing rear pinion bearing cone. The shims are (9) Install yoke with Installer D-191 for model 80
between the rear pinion bearing cone and pinion or C-3716A for model 60/70 and Wrench 6719 (Fig.
gear on model 60 axle and in the axle housing 39).
behind the rear bearing cup on model 70/80 axles (10) Install the yoke washer and a new nut on the
pinion gear. Tighten the nut to 258 N-m (190 ft. lbs.)
INSTALLATION COLLAPSIBLE
TOOL
SPACER
DRIVE
PINION GEAR
SHAFT
REAR BEARING
SHOULDER
REAR
BEARING
PINION
OIL GEAR
SLINGER
DRIVE
PINION GEAR J9003-67
J9302-66
Fig. 36 Shaft Rear Bearing Installation Fig. 37 Collapsible Preload Spacer—Model 60

for model 44 or 291 N-m (215 ft. lbs.) for model 60 NOTE: On model 60 and 70 axles, install yoke
minimum. Do not over tighten.Maximum torque is washer with concave surface against the yoke.
380 N-m (280 ft. lbs.).
PINION WASHER
YOKE
PINION
NUT
SLINGER
FRONT
BEARING
CUP
PINION
PRELOAD
SHIMS PINION
OIL SEAL
PINION PRELOAD
SPACER
FRONT
BEARING
CONE
SHOULDER FOR
J9203-63
• PINION PRELOAD SPACER
Fig. 38 Pinion Preload Shims—Model 70/80

BR — DIFFERENTIAL AND DRIVELINE 3 - 99
Fig. 39 Pinion Yoke installation—Typical

CAUTION; On model 60 axle, newer loosen pinion
gear nut to decrease pinion gear bearing preload
torque and never exceed specified preload torque.
If preload torque is exceeded a new collapsible
spacer must be installed. The torque sequence will
' Fig. 41 Check Pinion Gear Rotation Torque
have to be repeated.
(11) On model 60 axle, use Flange Wrench 6719 to
retain the yoke (Fig. 40). Slowly tighten the nut in STANDARD DIFFERENTIAL
small increments until the rotating torque is
achieved. Measure the preload torque frequently to DISASSEMBLE
avoid over tightening the nut. On model 70/80 axles (1) Clamp the differential case in a vise equipped
with soft jaws. Use a pin punch to remove the pinion
gear mate shaft lock pin (Fig. 42).
80a0c4f5
• Fig. 40 Tightening Pinion Nut

(12) Check bearing preload torque with an inch
pound torque wrench (Fig. 41). The torque necessary
to rotate the pinion gear should be:
• Original Bearings—1 to 3 N-m (10 to 20 in. lbs.).
• New Bearings—2 to 5 N-m (15 to 35 in. lbs.).
To achieve proper pinion bearing preload on model
70/80 axles, remove pinion gear from axle housing.
Increase shim thickness If rotation torque is to high. Fig. 42 Mate Shaft Lock Pin Removal
Decrease thickness i f rotation torque Is to low.
DISASSEMBLY AND ASSEMBLY (Continued)

(2) Remove the mate shaft with a drift and ham • Pinion gear mate shaft (align holes in shaft and
mer (Fig. 43). case)
(3) Install and seat the lock pin In differential case
and mate shaft with a punch and hammer (Fig. 45).
Peen metal part of case over pin in two places 180
degrees apart.
Fig, 43 Mate Shaft Removai

(3) Rotate the differential side gears and remove
the pinion mate gears and thrust washers (Fig. 44).
THRUST
WASHER
Fig, 45 Mate Shaft Pin instaiiation

I f replacement gears and thrust washers were
installed, i t is not necessary to measure the
gear backlash. Correct f i t is due to close
machining tolerances d u r i n g manufacture.
TRAC^LOI DIFFERENTIAL
The Trac-Lok (limited-slip) differential compo
nents are illustrated in (Fig. 46). Refer to this illus
tration during repair service.
DISASSEMBLY
Service to the Trac-Lok differential requires the
use of Tool Set C-4487 (J-23781). Refer to Model 44
MATE' GEAR SIDE GEAR J9203-61 Axle section i n this Group for Differential Removal
and Installation.
Fig, 44 Pinion Mate Gear Removal (1) Clamp Side Gear Holding Tool 6963 in a vise.
(4) Remove the differential side gears and thrust (2) Position the differential case on the holding
washers. tool (Fig. 47). Place shop towels under the differen
tial to avoid damage i f removal of the ring gear is
ASSEMBLE required (Fig. 47).
(1) Lubricate all differential components with (3) I f ring gear replacement is required, remove
hypoid gear lubricant. and discard the bolts holding the ring gear to the
(2) Install the following components In the differ case. Tap the ring gear with a rawhide or plastic
ential case. mallet and separate ring gear from case (Fig. 48).
• Differential side gears and thrust washers
• Pinion gears and thrust washers
BR DIFFERENTIAL AND DRIVELINE 3 -
J8903-43
Fig. 47 Differential Case Holding Tool

(4) Remove the pinion gear mate shaft lock screw SPECIAL
(Fig. 49). TOOL
C-4487-1
J9302-47
LOWER
Fig. 49 Mate Shaft Lock Screw SIDE
DIFFERENTIAL
CASE GEAR J9203-4
(5) Remove the pinion gear mate shaft. I f neces
sary, use a drift and hammer (Fig. 50).
Fig. 51 Step Plate Tool Installation
PINION MATE SHAFT
SOCKET
THREADED
ADAPTER
DISC
C-4487-3
THREADED
ROD
C-4487-2
DRIFT J9203-60
Fig. 50 Mate Shaft Removai

(6) Install and lubricate Step Plate C-4487-I (Fig.
51).
(7) Assemble Threaded Adapter C-4487-3 into top
DISC
side gear. Thread forcing Screw C-4487-2 into C-4487-1
J9203-1
adapter until i t becomes centered in adapter plate.
(8) Position a small screw driver in slot of Fig. 52 Threaded Adapter Installation
Threaded Adapter C-4487-3 (Fig. 52) to prevent
adapter from turning.
BR DIFFERENTIAL AND DRIVELINE 3-103
D I S A S S E M B L Y AND A S S E M B L Y ( C o n t i n u e d )
(9) Tighten forcing screw tool 122 N-m (90 ft. lbs.)
(maximum) to compress Belleville springs In clutch
packs (Fig. 53).
Fig. 55 Pinion Gear Removal
SIDE GEAR DIFFERENTIAL

A N D CLUTCH DISC CASE
Fig. 58 Tighten Beiieville Spring Compressor Tooi
(10) Using a 0.020 in. feeler gauge and mallet,
remove thrust washers from behind the pinion gears
(Fig. 54).
RE*
Fig. 56 Side Gear & Clutch Disc Removal

(14) Remove case from fixture. Remove remaining
clutch pack.
(15) Remove clutch pack retaining clips. Mark
each clutch pack for installation reference.
ASSEMBLY
Fig. 54 Remove Pinion Thrust Washer
The clutch discs are replaceable as complete sets
(11) Loosen the forcing screw tool until the clutch only. If one clutch disc pack is damaged, both
pack tension is relieved and the pinion gears can be packs must be replaced.
slightly rattled between the case and side gears. Lubricate each component with gear lubricant
(12) Insert Turning Bar C-4487-4 in case. Rotate before assembly.
case with tool until pinion gears can be removed (Fig. (1) Assemble the clutch discs into packs secure
55). disc packs with retaining clips (Fig. 57).
(13) Remove top side gear and clutch pack. Keep (2) Position assembled clutch disc packs on the
plates i n correct order during removal (Fig. 56). side gear hubs.
(3) Position case on axle fixture.
3 - 114 DIFFERENTIAL AND DRIVELINE mm
CLUTCH PACK UPPER SIDE

GEAR A N D CLUTCH
RETAINER DISC PACK
DIFFERENTIAL
CASE
SIDE G E A R
RETAINER
J8903-50 SPECIAL TOOL
C-4487-1 J9203-6
Fig. 57 dutch Disc Pack

Fig. 59 Upper Side Gear & Clutch Disc Pack
(4) Install clutch pack and side gear in lower bore Installation
(Fig. 58). Be sure clutch pack retaining clips
(10) Rotate case with Turning Bar C-4487-4 until
remain in position and are seated in the case
mate shaft holes in pinion gears align with holes in
pockets.
case.
LOWER (11) Tighten forcing screw to 122 N-m (90 ft. lbs.)
DIFFERENTIAL SIDE GEAR to compress the Belleville springs. Lubricate and
CASE AND install thrust washers behind pinion gears and align
CLUTCH DISC
PACK
washers with a small screw driver. Insert mate shaft
into each pinion gear to verify alignment.
(12) Remove forcing screw, threaded adapter and
step plate. Install pinion gear mate shaft, align holes
in shaft and case.
(13) Install the pinion mate shaft lock screw finger
tight to hold shaft during installation.
If replacement gears and thrust washers were
installed, it is not necessary to measure the
gear backlash. Correct fit is due to close
machining tolerances during manufacture.
J9003-4 (14) Lubricate all differential components with
Fig. 58 Clutch Discs & Lower Side Gear Installation
(5) Install lubricated Step Plate C-4487-1 on first POWER-LOK—MODEL 70/TRAC-LOK—MODEL 80
clutch pack (Fig. 59). The Trac-Lok differential for the Model 80 axle
(6) Install the upper side gear and clutch disc pack looks like the Power-Lok differential for the Model 70
(Fig. 59). axle but their are differences.
(7) Hold assembly in position. Insert Threaded The Model 80 Trac-Lok differential has a one-piece
Adapter C-4487-3 into top side gear, insert forcing cross shaft and uses 6 disc and 5 plates for each
Screw C-4487-2. clutch pack. Only one disc in each clutch pack is
(8) Tighten forcing screw tool to slightly compress dished.
clutch discs. The Model 70 Power-Lok differential has a two-
(9) Place pinion gears in position in side gears and piece cross shaft and uses 2 disc and 3 plates for
verify that mate shaft hole line up. each clutch pack. All disc are dished i n this unit.
EINSTALLATION
_ REFERENCE-y^
BUTTON
HALF
CLUTCH
PLATES
FLANGE
HALF
J9203-72
J9203-73
Fig. 60 Case Marked Fig. 61 Cover Half Removal

DISASSEMBLE (3) Remove the pinion mate gear, side gear (clutch)
Pay close attention to - the clutch pack ring and clutch pack cross shaft (Fig. 62), (Fig. 63).
arrangement d u r i n g this procedure. Note the Keep these parts with the button cover half for cor
direction of the concave and convex side of the rect installation in their original positions.
plates and discs. (4) Remove the same parts listed above from the
(1) Mark the ring gear half and cover half for ring gear flange half of the case. Keep these parts
installation reference (Fig. 60). with the flange cover half for correct installation i n
(2) Remove the case attaching bolts and remove their original positions.
the button cover half (Fig. 61).
F L A N G E HALF SIDE
GEAR
PINION M A T E
GEAR
B U T T O N HALF
PLATE
CROSS SHAFT
J9503-8
Fig. 62 Trac-Lok Dana 80 Components

FLANGE HALF CLUTCH P I N I O N MATE

RING GEAR
SCREW
PLATE DISHED PLATE DISHED PINION MATE

DISC DISC CROSS SHAFT BUTTON HALF
J9203-74
Fig. 63 Power-Lok Components
ASSEMBLE (2) Line up the plate ears and install the assem
The clutch discs are replaceable as complete sets bled pack into the flange half (Fig. 65). Make sure
only. I f one clutch disc pack is damaged, b o t h the clutch plate lugs enter the slots in the case.
packs must be replaced. Lubricate each component Also make sure the clutch pack bottoms out on
with gear lube before assembly and installation. the case.
(1) Saturate the clutch plates with Hypoid Gear
Lubricant or Additive. Assemble clutch packs into the
side gear plate in exactly the same position as
removed (Fig. 62), (Fig. 63), or (Fig. 64).
CLUTCH
PLATES
J9203-77
Fig. 65 dutch Pack installation

CLUTCH
RING J9203-76
Fig. 64 Clutch Pack Power-Lok

B R - — — DIFFERENTIAL AND DRIVELINE 3 -107

(3) Install pinion mate shafts and pinion mate
gears (Fig. 66). Make sure shafts are correctly
installed according to the alignment marks.
SIDE GEAR
ALIGNMENT PINION G E A R S Fig. 87 Case Half installation

MARKS A N D MATE SHAFT J9203-78
• Raised metal on shoulders of cup bores should
Fig. 66 dutch Pack Instaiiation be removed with a hand stone
• Wear and damage to pinion gear mate shaft,
(4) Lubricate and install the other side gear and pinion gears, side gears and thrust washers. Replace
clutch pack (Fig. 65). as a matched set only.
(5) Correctly align and assemble button half to • Ring and pinion gear for worn and chipped teeth
flange half. Install case body screws finger tight. • Ring gear for damaged bolt threads. Replaced as
(6) Tighten body screws alternately and evenly. a matched set only.
Tighten screws to 89-94 N-m (65-70 ft. lbs.) torque • Pinion yoke for cracks, worn splines, pitted
(Fig. 67). areas, and a rough/corroded seal contact surface.
If bolt heads have 7 radial lines or the number 180 Repair or replace as necessary.
stamped on the head, tighten these bolts to 122-136 • Preload shims for damage and distortion. Install
N-m (90-100 ft. lbs.) torque. new shims i f necessary.
CLEANING AND INSPECTION TRAC-LOK AND POWER-LOK

(1) Clean all components in cleaning solvent. Dry
AXLE COMPONENTS components with compressed air.
Wash differential components with cleaning solvent (2) Inspect clutch pack plates for wear, scoring or
and dry with compressed air. Do not steam clean damage. Replace both clutch packs i f any one compo
the differential components. nent in either pack is damaged.
Wash bearings with solvent and towel dry, or dry (3) Inspect side and pinion gears. Replace any gear
with compressed air. DO NOT spin bearings with that is worn, cracked, chipped or damaged.
compressed air. Cup and bearing must be (4) Inspect differential case and pinion shaft.
replaced as matched sets only. Replace i f worn or damaged.
Clean axle shaft tubes and oil channels in housing.
PRESOAK PLATES AND DISC
Inspect for;
Plates and discs with fiber coating (no grooves or
• Smooth appearance with no broken/dented sur
lines) must be presoaked in Friction Modifier before
faces on the bearing rollers or the roller contact sur
assembly. Soak plates and discs for a minimum of 20
faces
minutes. Add remaining Friction Modifier to differen
• Bearing cups must not be distorted or cracked
tial after assembly.
• Machined surfaces should be smooth and with
out any raised edges
3-108 DIFFERENTIAL AND DRIVELINE — BR
ADJUSTMENTS INNER PINION
PINION GEAR DEPTH
GENERAL INFORMATION
Gears are supplied as matched sets only. The Iden
tifying numbers for the ring and pinion gear are
etched into the face of each gear (Fig. 68). A plus (+)
number, minus (-) number or zero (0) is etched into STANDARD
the face of the pinion gear. This number is the DEPTH
amount (in thousandths of an inch) the depth varies
from the standard depth setting. The standard depth
provides the best teeth contact pattern.
DRIVE PINION
Fig. 69 Pinion Gear Standard Depth/Distance
Fig. 68 Pinion Gear ID Numbers

The standard depth is the distance (Fig. 69) from
the centerline of the axle shaft/ring gear to the shoul
der of the rear pinion bearing.
• Model 60 axle, the standard depth/distance is
127.00 mm (5.000 inches)
136.525 mm (5.375 inches).
147.625 mm (5.812 inches).
Compensation for depth variance is achieved by Fig. 70 Shim Locations
two methods. One method is shims placed between Subtract this amount from original shim. Refer to
the pinion gear rear bearing cup and housing (Fig. the Pinion Gear Depth Variance Chart.
70). The second method is selective shim between the If equipped, the oil slinger must be measured
pinion gear head and bearing cone. and the thickness included with the total shim
If new gear set is being installed, note the depth pack thickness.
variance etched into original and new pinion gear.. Depth shim thickness for the new pinion gear must
Add or subtract the thickness of the original depth be determined before installing differential case in
shims to compensate for the difference in the depth housing.
variances. Refer to the Depth Variance charts.
For example, i f old pinion is plus (+) 1 and the new PINION DEPTH MEASUREMENT AND
pinion is minus ( - ) 3, intersecting figure is (+) 0.004 ADJUSTMENT
inch (0.10mm). Add this amount to the original shim. Pinion gear depth measurement is necessary
Or i f the old pinion is (-) 3 and the new pinion is (-) when;
2, intersecting figure is (-) 0.001 inch (0.025mm). ® Axle housing or differential case is replaced
• Pinion select shim pack is unknown
• Ring and pinion gears are replaced
BR DIFFERENTIAL AND DRIVELINE 3 -109
Original Pinion Replacement Pinion Gear Depth Variance

G e a r Depth
Variance -4 -3 -1 0 + 1 + 2 + 3 +4
+4 + 0.008 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0
+3 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001
+2 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002
+ 1 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003
§ + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004
+ 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005
-2 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006
-3 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007
-4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008
J8902-46
Measurements are taken with pinion cups and pin (1) Assemble Pinion Gauge Set, Pinion Block and
ion bearings installed in housing. Take measure pinion bearings. Install assembly into differential
ments with Pinion Gauge Set 6730. Use Pinion Block pinion gear bore and hand tighten cone (Fig. 72).
6734 for Model 44 and 6736 for model 60 axle. Use
PINION BLOCK
Dial Indicator C-3339 dial indicator to measure dif
ference in height of the arbor and the pinion block.
(Fig. 71).
DIAL INDICATOR
PINION HEIGHT
BLOCK CONE o
\ /
PINION HEIGHT
BLOCK
J9403-39
SCREW
Fig. 72 Pinion Height Block—Typical

PINION BLOCK
(2) Place Arbor Disc 6732 on Arbor D-115-3 and
position in the bearing cradles (Fig. 73). Install dif
SCOOTER BLOCK ferential bearing caps on Arbor Discs and tighten
caps snug only.
Arbor Discs have different steps. to fit other
ARBOR DISC
axle sizes. Pick correct size step for axle being
serviced.
J9403-45
(3) Firmly place Scooter Block D-115-2 and Dial
Fig. 71 Pinion Gear Depth Gauge Tools—Typical Indicator on pinion height block tool and zero the
dial indicator pointer.
(4) Slide the Scooter Block across the arbor while
observing indicator (Fig. 74). Record the longest
(1) Install dummy side bearings D-343 on differen
ARBOR DISC PINION BLOCK tial.
(2) Install the differential case in the axle housing.
' (3) Install the outboard shim/spacer (selected thick
ness) on each side between bearing cup and housing (Fig.
75). Use 0.142 in. (3.6 mm) as a starting point, shim/
spacers are available in various thicknesses.
INSTALL
0.142-IN. (3.6-AAAA) THICK
SHIM
EACH SIDE
ARBOR
PINION
HEIGHT BLOCK J9403-37
Fig. 73 Gauge Tools in Housing—Typical
travel distance, whether inward (-) or outward (+),
indicated by the pointer.
DIFFERENTIAL -
CASE J9003-27
Fig. 75 Differential Bearing Shim Installation
(4) Install the marked bearing caps in their correct
positions. Install and snug the bolts.
(5) Attach a dial indicator to the housing. Position
the indicator plunger so that it contacts the ring gear
mating surface (Fig. 76).
J9403-38
DIAL
Fig. 74 Pinion Gear Depth Measurement- Typical INDICATOR
The plunger travel distance indicated, plus or DIFFERENTIAL
minus the variance etched in the gear is the CASE
required thickness for the depth shims.
(5) Measure the thickness of each depth shim with
a micrometer and combine the shims necessary for
total required shim pack thickness. Include oil
slinger or baffle thickness with the total shim
pack thickness.
(6) Remove the measurement tools from the differ
ential housing.
DIFFERENTIAL BEARING PRELOAD AND GEAR

LASH
This procedure requires tool kit 6770 to determine
the proper differential side gear preload.
RING
GEAR
DIFFERENTIAL SHIM PACK MEASUREMENT AAATING
FACE
NOTE: It is recommended whenever bearings are J9003-28
removed that they be replaced. Fig. 76 Shim Measurement
(6) Pry the differential case to one side and zero I f backlash must be adjusted, spacers are available
the dial indicator pointer. in various thicknesses. Adjust the backlash - accord
(7) Pry the differential case to the opposite side ingly (Fig. 78). Do not increase the total shim
and record indicator reading. Reading is additional pack thickness, excessive bearing preload and
shim thickness needed for zero end play. For exam damage will occur.
ple, i f reading was 0.008 in. (0.20 mm), an additional
0.004-in. (0.10 mm) thick shim will be needed at
each side zero end play.
(8) Install zero end-play shims on each side of
case.
The differential bearings must be preloaded
to compensate for heat and load during opera
tion.
(9) Add an additional 0.004-in. (0.1 mm) to each
outboard shim/spacer for bearing preload.
(11) Remove dummy bearings.
(12) Install new side bearing cones and cups.
(13) Install ring gear.
(14) Install differential and verify gear lash and
contact pattern.
(15) Proceed to Final Assembly paragraph in this
section.
GEAR BACKLASH AND CONTACT PATTERN

ANALYSIS " FOR LESS BACKLASH — — *
J9302-28
After installing new side bearings or ring and pin
ion set adjusting the bearing perload and gear mash
Fig. 78 Backlash Shim Adjustment
backlash will be necessary.
(1) Rotate assembly several revolutions to seat The ring gear teeth contact patterns will show i f
bearings. Measure backlash at three equally spaced the pinion gear depth shim(s) have the correct thick
locations around the perimeter of the ring gear with ness. It will also show i f the ring gear backlash has
a dial indicator (Fig. 77). been adjusted correctly. The backlash must be main
tained within the specified limits until the correct
tooth contact patterns are obtained.
(2) Apply a thin coat of hydrated ferric oxide, or
equivalent, to the drive and coast side of the ring
gear teeth.
(3) Rotate the ring gear one complete revolution i n
both directions while a load is being applied. Insert a
pry bar between the differential housing and the case
flange. This will produce distinct contact patterns on
both the drive side and coast side of the ring gear
teeth.
(4) Note patterns in compound. Refer to (Fig. 79)
for interpretation of contact patterns and adjust
accordingly.
Fig. 77 Ring Gear Backlash Measurement

The ring gear backlash must be within 0.12 -
0.20 mm (0.005 - 0.008 in.). It cannot vary more
than 0.05 mm (0.002 in.) between the points
checked.
DRIVE SIDE C O A S T SIDE

O F RING O F RING
DESIRABLE C O N T A C T PATTERN.
PATTERN S H O U L D BE CENTERED
H E E ^ ^ ^ ^ ^ ^ ^ T O E T O E ^ ^ ^ ^ ^ ^ ^ ^ ^ t L
PATTERN S H O U L D BE CENTERED O N
THE C O A S T SIDE O F T O O T H ,
THE T O E . THERE S H O U L D ALWAYS
THE T O O T H .

SHIM REQUIRED.
RING GEAR BACKLASH CORRECT

SHIM REQUIRED.

CORRECT. D E C R E A S E RING
• GEAR BACKLASH.
IS
CORRECT. I N C R E A S E RING
GEAR BACKLASH.
J9003-24
Fig. 79 Gear Tooth Contact Patterns
SPECIFICATIONS MODEL 80 AXLE
MODEL 60/70/80 REAR AXLES DESCEIPTION ' SPEC.

Axle Type .Hypoid
MODEL 60 AXLE Lubricant. . . . . .Thermally Stable SAE 80W-90
Lube Capacity
DESCRIPTION SPEC. 4x2 .3.22 L (6.8 pts.)
Axle Type .Hypoid 4x4. . .4.79 L (10.1 pts.)
Lubricant. Thermally Stable SAE 80W-90 Axle Ratio . .. .3.54 4.10
Lube Capacity Ring Gear
4x2 .2.95 L (6.26 pts.) Diameter 279.4 mm (11.00 in.)
4x4 .3.43 L (7.25 pts.) Backlash 0 13--0.23 mm (0.005-0.009 in.)
Axle Ratio . .3.54 4.09 Pinion Std. Depth. 124.625 mm (5.812 in.)
Ring Gear Pinion Bearing Preload
Diameter .247.7 mm (9.75 in.) Original Bearing. . , 1-3 N-m (10-20 in. lbs.)
Backlash . . . . . . . . . .0.10-0.23 mm (0.004-0.009 In.) New Bearing. . . . . . 2-5 N-m (20-40 in. lbs.)
Pinion Std. Depth . . .127.0 mm (5.000 in.)
Pinion Bearing Preload TORQUE
Original Bearing. 1-3 N-m (10-20 in. lbs.)
New Bearing. . . . . . . . . . . . .2-5 N-m (20-40 in. lbs.) DESCRIPTION TORQUE
DIFFERENTIAL
MODEL 70 AXLE Fill Hole Plug 34 N-m (25 ft. lbs.)
Cover Bolts . . 47 N-m (35 ft. lbs.)
DESCEIPTION SPEC. Bearing Cap Bolts, 108 N-m (80 ft. lbs.)
Axle T^pe .Hypoid PINION NUT
Lubricant. Thermally Stable SAE 80W-90 Model 60 . . . . 292--427 N-m (215-315 ft. lbs.)
Lube Capacity Model 70 298--379 N-m (220-280 ft. lbs.)
4x2 3.311 L (7.0 pts.) Model 80 597--678 N-m (440-500.ft. lbs.)
4x4. . . . . . . . . . . . . . . . . . . . .3.666 L (7.75 pts.) * RING GEAR BOLT
Axle Ratio . . . . . . . . . . . . . . . . . . . . . . . . . .3.54 4.10 Model 60 & 70 163--190 N-m (120-140 ft. lbs.)
Ring Gear Model 80 .272--325 N-m (200-240 ft. lbs.)
Diameter .266.7 mm (10.50 In.) Axle to Hub Bolt 123 N-m (90 ft. lbs.)
Backlash 0.10-0.23 mm (0.004-0.009 in.) POWER-LOK CASE BOLT
Pinion Std. Depth. . . . . . . . . .136.525 mm (5.375 in.) Standard 89-94 N-m (65-70 ft. lbs.)
Pinion Bearing Preload Heavy Duty 122-136 N-m (90-100 ft. lbs.)
Original Bearing 1-3 N-m (10-20 in. lbs.) RWAL/ABS Sensor Bolt 24 N-m (18 ft. lbs.)
New Bearing 2-5 N-m (20-40 in. lbs.)
Puller—C-452
BR . . DIFFERENTIAL AND DRIVELINE 3
Installer, Differential Bearing—iC-4190

3 -116 DIFFERENTIAL AND DRIVELINE
Remover, Pinion Bearing Cup—D-159

Handle, Drive—C-4735
BR DIFFERENTIAL AND DRIVELINE 3-
Installer, Pinion Seal—D-187B

Spreader, Differential—W-129B
BRAKES 5 - 1
BRAKES
CONTENTS
page page
BASE BRAKE SYSTEM 1 REAR WHEEL ANTILOCK (RWAL) BRAKES . . . . 46

FOUR WHEEL ANTILOCK BRAKE SYSTEM . . . . 70
BASE BRAKE SYSTEM
INDEX
page page
G E N E R A L INFORMATION BRAKESHOE (11 INCH BRAKE) 30

BRAKE SYSTEM 2 BRAKESHOE (13-INCH BRAKE) 32
SERVICE WARNINGS & CAUTIONS 2 DISC BRAKE CALIPER 24
DESCRIPTION AND OPERATION DISC BRAKE ROTOR (WITH TAPERED
BRAKE HOSES AND LINES 8 BEARINGS) 28
Brake Pedal 2 DISC BRAKE ROTOR (WITH UNIT BEARINGS) . 29
COMBINATION VALVE 5 DISC BRAKESHOE 25
DRUM BRAKES 7 FRONT PARKING BRAKE CABLE 34
FRONT DISC BRAKES 6 FRONT WHEEL BEARING 30
MASTER CYLINDER 5 MASTER CYLINDER 19
PARKING BRAKES 7 PARKING BRAKE PEDAL 36
POWER BRAKE VACUUM PUMP (DIESEL POWER BRAKE BOOSTER 20
MODELS) 4 POWER BRAKE VACUUM PUMP (DIESEL
Power Brake Booster 3 ENGINE) 21
RED BRAKE WARNING LAMP 3 REAR PARK BRAKE CABLE 35
STOP LAMP SWITCH 2 RWAL VALVE/COMBINATION VALVE 18
DIAGNOSIS AND TESTING STOP LAMP SWITCH 16
BASE BRAKE SYSTEM 8 WHEEL CYLINDER 34
BRAKE DRUM 13 DISASSEMBLY AND ASSEMBLY
BRAKE FLUID CONTAMINATION 13 DISC BRAKE CALIPER 38
BRAKE LINE AND HOSES 13 MASTER CYLINDER 36
COMBINATION VALVE 12 WHEEL CYLINDER 41
DIESEL ENGINE VACUUM PUMP OUTPUT 11 CLEANING AND INSPECTION
DISC BRAKE ROTOR 12 CALIPER 41
MASTER CYLINDER/POWER BOOSTER 11 REAR DRUM BRAKE 41
RED BRAKE WARNING LAMP 10 WHEEL CYLINDER 42
STOP LAMP SWITCH 10 ADJUSTMENTS
SERVICE PROCEDURES PARKING BRAKE CABLE TENSIONER
BRAKE BLEEDING 15 ADJUSTMENT 44
BRAKE DRUM MACHINING 16 REAR DRUM BRAKE 42
BRAKE FLUID LEVEL 14 STOP LAMP SWITCH 42
BRAKE LINE 16 SPECIFICATIONS
DISC ROTOR MACHINING 15 BASE BRAKE 45
MASTER CYLINDER BLEEDING 14 BRAKE FLUID 44
REMOVAL AND INSTALLATION TORQUE CHART 45
BRAKE PEDAL 17 SPECIAL TOOLS
BRAKE SUPPORT PLATE 34 BASE BRAKES 45
5 - 2 BRAKES — — — BR
GENERAL INFORMATION ination is suspected, check the fluid for dirt, discol
oration, or separation into distinct layers. Drain and
BRAKE SYSTEM flush the system with new brake fluid if contamina
This vehicle is equipped with front disc brakes and tion is suspected.
rear drum brakes. The front disc brakes consist of
single piston calipers and ventilated rotors. The rear
CAUTION: Use Mopar brake fluid, or an equivalent
brakes are dual brakeshoe, internal expanding units
quality fluid meeting SAE/DOT standards J1703 and
with cast brake drums. The parking brake mecha
DOT 3. Brake fluid must be clean and free of con
nism is cable operated and connected to the rear
taminants. Use fresh fluid from sealed containers
brake trailing shoes. Power brake assist is standard
only to ensure proper antilock component opera
equipment. A vacuum operated power brake booster
is used for all applications. tion.
Use Mopar multi-mileage or high temperature
Two antilock brake systems are used on this vehi
grease to lubricate caliper slide surfaces, drum
cle. A rear wheel antilock (RWAL) brake system is
brake pivot pins, and shoe contact points on the
standard. An all-wheel antilock brake system (ABS)
backing plates. Use multi-mileage grease or GE 661
is available as an option. The RWAL and ABS sys
or Dow 111 silicone grease on caliper bushings and
tems are designed to retard wheel lockup while brak
slide pins to ensure proper operation.
ing. Retarding wheel lockup is accomplished by
modulating fluid pressure to the wheel brake units.
Both systems are monitored by a microprocessor
which controls the operation of the systems*. D E S C R I P T I O N AMD OPERATION
SERVICE WARNINGS 1 CAUTIONS Brake Pedal

The brake booster is operated by a suspended type
WARNING: DUST AND DIRT ACCUMULATING ON brake pedal (Fig. 1). The pedal pivots on a shaft
B R A K E PARTS DURING NORMAL U S E MAY CON located in a mounting bracket attached to the dash
TAIN A S B E S T O S F I B E R S . BREATHING E X C E S S I V E panel. The pedal shaft is supported by bushings in
CONCENTRATIONS OF A S B E S T O S F I B E R S CAN the pedal and mounting bracket.
CAUSE SERIOUS BODILY HARM. EXERCISE CARE
WHEN SERVICING B R A K E PARTS. DO NOT C L E A N PEDAL SHAFT
BRAKE PARTS WITH COMPRESSED AIR OR BY

DRY BRUSHING. U S E A VACUUM C L E A N E R S P E
CIFICALLY DESIGNED FOR THE REMOVAL OF
A S B E S T O S F I B E R S FROM B R A K E COMPONENTS.
IF A SUITABLE VACUUM C L E A N E R IS NOT AVAIL
A B L E , CLEANING SHOULD B E DONE WITH A
WATER DAMPENED CLOTH. DO NOT SAND, OR
GRIND B R A K E LINING U N L E S S EQUIPMENT USED
IS DESIGNED TO CONTAIN THE DUST RESIDUE.
DISPOSE OF A L L RESIDUE CONTAINING A S B E S
TOS F I B E R S IN S E A L E D B A G S OR CONTAINERS
TO MINIMIZE E X P O S U R E TO Y O U R S E L F AND OTH
ERS. FOLLOW P R A C T I C E S P R E S C R I B E D BY THE
OCCUPATIONAL S A F E T Y AND HEALTH ADMINIS
TRATION AND THE ENVIRONMENTAL PROTECTION
AGENCY FOR THE HANDLING, P R O C E S S I N G , AND
DISPOSITION OF DUST OR DEBRIS THAT MAY
CONTAIN ASBESTOS FIBERS.
CAUTION: Never use gasoline, kerosene, alcohol,

motor oil, transmission fluid, or any fluid containing Fig. 1 Brake Pedal
mineral oil to clean the system components. These STOP LAiP SWITCH
fluids damage rubber cups and seals. Use only The plunger type stop lamp switch is mounted on a
fresh brake fluid or Mopar brake cleaner to clean or bracket attached to the brake pedal support. The
flush brake system components. These are the only switch can be adjusted when necessary.
cleaning materials recommended. If system contam
SBF1 BRAKES 5-3
0ESCHIPT1OH AMD ©PEKATf®li f C o n f l n y e d )
RED BRAKE WARNING LA1P POWER BRAKE BOOSTER OPERATION
A red warning lamp is used for the service brake The booster assembly consists of a housing divided
portion of the hydraulic system. The lamp is located into separate chambers by two internal diaphragms.
in the instrument panel. The outer edge of each diaphragm is attached to the
The red warning light alerts the driver i f a pres booster housing. The diaphragms are in turn, con
sure differential exists between the front and rear nected to the booster push rod.
hydraulic systems. The light also alerts the driver Two push rods are used to operate the booster. One
when the parking brakes are applied. push rod connects the booster to the brake pedal. The
second push rod (at the forward end of the housing),
Power Brake Booster strokes the master cylinder pistons. The rear push
All BR models are equipped with a tandem (dual) rod is connected to the two diaphragms in the
diaphragm power brake booster (Fig. 2). Two versions booster housing.
are used. A standard duty is used in all 1/2 ton mod The atmospheric Inlet valve is opened and closed
els and a higher output version Is used in 3/4 and 1 by the push rod connected to the brake pedal. The
ton models. The standard and high output boosters booster vacuum supply is through a hose attached to
are identified by code letters on the forward face of a fitting on the intake manifold. The hose is con
the booster (Fig. 2). nected to a vacuum check valve in the booster hous
Booster I.D. code letters are as follows: ing. The check valve is a one-way device that
• 1/2 ton booster code: ZK prevents vacuum leak back.
• 3/4 and 1 ton booster code: ZL Power assist is generated by utilizing the pressure
The only serviceable power brake booster compo differential between normal atmospheric pressure
nents are the vacuum hose and check valve. The and a vacuum. The vacuum needed for booster oper
booster itself is not a repairable component. The ation is taken directly from the engine intake mani
booster must be replaced as an assembly whenever fold. The entry point for atmospheric pressure is
diagnosis indicates a fault has occurred. through an inlet valve at the rear of the housing.
The forward portion of the booster housing (area in
front of the two diaphragms), is exposed to manifold
IDENTIFICATION BOOSTER INTEGRAL BOOSTER

CODE PUSH ROD MOUNTING PUSH ROD
LOCATION (TO MASTER BRACKET (TO BRAKE
CYLINDER) PEDAL)
CHECK
VALVE
BOOSTER
MASTER MOUNTING
CYLINDER STUDS
MOUNTING
STUDS
FRONT VIEW SIDE VIEW REAR VIEW
J9405-20
Fig. 2 Power Brake Booster

5 4 BRAKES BR
DESCRIPTION AND OPERATION (Continued)

vacuum. The rear portion (area behind the dia VACUUM
phragms), is exposed to normal atmospheric pressure
of 101.3 kilopascals (14.7 psi).
Pressing the brake pedal causes the rear push rod
to open the inlet valve. This exposes the area behind
the diaphragms to atmospheric pressure. The result
ing force applied to the diaphragms is what provides
the extra' boost in apply pressure for power assist.
POWER BRAKE VACUUM PUMP (DIESEL MODELS)

The power brake vacuum pump and the power
steering pump are combined into a single assembly
on diesel engine models (Fig. 3). Both pumps are
operated by a drive gear attached to the vacuum
pump shaft. The shaft gear is driven by the camshaft
gear.
The vacuum pump is a constant displacement,
vane-type pump. Vacuum is generated by four vanes
mounted in the pump rotor. The,rotor is located In GEAR ADAPTER
the pump housing and is pressed onto the pump J9105-94
shaft.
The vacuum and steering pumps are * operated by a Fig. 3 Diesel Vacuum & Power Steering Pump
single drive gear pressed onto the vacuum pump Assembly
shaft. The drive gear is operated by the engine cam The switch is mounted on the driver .side Inner
shaft gear. fender panel just below the hood hinge (Fig. 4). The
The vacuum and power steering pump shafts are switch is located just under the front antilock valve
connected by a coupling. Each pump shaft has an on ABS models.
adapter with drive lugs that engage in the coupling.
. The vacuum pump rotating components are lubri
cated by engine oil. Lubricating oil is supplied to the
pump through an oil line at the underside of the
pump housing.
The complete assembly must be removed in order
to service either pump. However, the power steering
pump can be removed and serviced separately when
necessary.
The vacuum pump is not a serviceable component.
I f diagnosis indicates a pump malfunction, the pump
must be replaced as an assembly. Do not disassemble
or attempt to repair the pump.
The combined vacuum and steering pump assem
bly must be removed for access to either pump. How
ever, the vacuum pump can be removed without
having to disassemble the power steering pump.
I f the power steering pump requires service, simply Fig. 4 Diesel Vacuum Switch Location (Without
remove the assembly and separate the two pumps. ABS)
Refer to the pump removal and installation proce VACUUM PUMP OPERATION
dures i n this section. Vacuum pump output is transmitted to the power
brake booster through a supply hose. The hose is con
LOW VACUUM WARNING switch
nected to an outlet port on the pump housing and to
A vacuum switch is used to monitor output of the the check valve i n the power brake booster.
vacuum pump. The switch is in circuit with the red Pump output ranges from a minimum of 8.5 to 25
brake warning light. inches vacuum.
A vacuum hose connects the switch to the power The pump rotor and vanes are rotated by the pump
brake booster. A wire harness connects the switch to drive gear. The drive gear is operated by the cam
the brake warning light. shaft gear.
BR BRAKES i -S
Booster vacuum level is monitored by a warning
switch. The switch consists of a vacuum chamber
that measures vacuum level and a sensor in circuit
with the red brake warning light.
The vacuum chamber is connected to the booster
check valve by a vacuum supply hose. A wire harness
connects the switch sensor to the brake warning
light. I f booster vacuum falls below 8.5 Inches for
8-10 seconds or more, the switch sensor completes'
the circuit to the warning light causing i t to illumi
nate.
1ASTER CYLINDER
BR models are equipped with a two-section master
cylinder assembly. Major components are the alumi
num cylinder body and a removable plastic reservoir
(Fig. 5).
The primary and secondary pistons are located in
the cylinder body. Grommets are used to secure and
seal the reservoir in the cylinder body. The reservoir
cover is equipped with diaphragm seal and is a snap
fit on the reservoir.
The cylinder body is equipped with a quick take-up
valve located in the primary piston inlet port (Fig. 5).
The valve provides an extra volume of low pressure
fluid during Initial brake apply. Extra fluid volume
provides faster take-up of normal clearances in the
calipers and wheel cylinders.
The cylinder body, piston assemblies, reservoir,
grommets, seal and cover are all serviceable parts.
The take-up valve is the only non-serviceable compo
nent. The valve is available only as part of a com
plete cylinder body assembly. PRIMARY
PISTON
APPLICATION ASSEMBLY J9405-13
Three master cylinders are used i n BR models. The
differences between' them concern cylinder bore size Fig. 5 Master Cylinder
and fluid reservoir capacity. The cylinder body code letters are etched into the
• The master cylinder in 1500 models has a 28.6 front end of the cylinder. The reservoir code letters
mm (1.125 in.) bore. are on an adhesive backed tag attached to the front
• The master cylinder in 2500 and 3500 models face of the reservoir (Fig. 6).
has a 31.8 mm (1.252 in.) bore. Code letters are as follows:
Although the master cylinders used in 2500 and * 1/2 ton (Model 1500) code: NK
3500 models have the same bore size, they have dif- . • * 3/4 ton (Model 2500) code: NL
ferent piston stroke lengths and fluid reservoir • 1 ton (Model 3500) code: NP
capacities.
COMBINATION VALVE
NOTE: Master cylinders and reservoirs must not be
interchanged. This will cause unsatisfactory opera Pressure Differential Switch
tion and improper brake balance. The pressure differential switch is connected to the
brake warning lamp. The switch is triggered by
IDENTIFICATION CODES
movement of the switch valve. The purpose of the
The master cylinder and reservoir are coded for switch is to monitor fluid pressure i n the separate
identification. Code letters are provided on the cylin front/rear brake hydraulic circuits.
der body and reservoir for proper component match A decrease or loss of fluid pressure in either
ing. hydraulic circuit will cause the switch valve to shut-
S-i BRAKES BR
Fig. 6 identification Code Locations

Fig. 7 Brake Caliper Operation
tie forward or rearward in response to the pressure
differential. Movement of the switch valve will push the piston bore forces the caliper to slide Inward on
the switch plunger upward. This closes the switch the mounting bolts. This action brings the outboard
Internal contacts completing the electrical circuit to brakeshoe lining into contact with the outer surface
the warning lamp. The switch valve may remain i n of the disc brake rotor.
an actuated position until repair restores system In summary, fluid pressure acting simultaneously
pressures to normal levels. on both piston and caliper, produces a strong clamp
ing action. When sufficient force is applied, friction
Metering Valve will stop the rotors from turning and bring the vehi
The metering valve Is used to balance brake action cle to a stop.
between the front disc • and rear drum brakes. The Application and release of the brake pedal gener
valve meters (holds-off) full apply pressure to the ates only a very slight movement of the caliper and
front disc brakes,until the rear brakeshoes are i n full piston. Upon release of the pedal, the caliper and pis
contact with the drums. The valve Is designed to ton return to a rest position. The brakeshoes do not
maintain front brake fluid pressure at 21-207 kPa retract an appreciable distance from the rotor. I n
(3-30 psi) until the hold-off limit of 807 kPa (117 psi) fact, clearance is usually at, or close to zero. The rea
is reached. At this point, the metering valve opens sons for this are to keep road debris from getting
completely permitting full fluid apply pressure to the between the rotor and lining and in wiping the rotor
front disc brakes. surface clear each revolution.
The caliper piston seal controls the amount of pis
FRONT DISC BRAKES ton extension needed to compensate for normal lining
The calipers are a single piston type. The calipers wear.
are free to slide laterally, this allows continuous com During brake application, the seal Is deflected out
pensation for lining wear. ward by fluid pressure and piston movement (Fig. 8).
When the brake are applied fluid pressure is When the brakes (and fluid pressure) are released,
exerted against the caliper piston. The fluid pressure the seal relaxes and retracts the piston.
is exerted equally and In all directions. This means The amount of piston retraction is determined by
pressure exerted against the caliper piston and brakelining wear. Generally the amount is just
within the caliper bore will be equal (Fig. 7). enough to maintain contact .between the piston and
Fluid pressure applied to the piston Is transmitted Inboard brakeshoe.
directly to the inboard brakeshoe. This forces the
shoe lining against the inner surface of the disc
brake rotor. At the same time, fluid pressure within
BR BRAKES 5-7
lever, actuating lever (11 inch brake), lever return

spring and the adjuster lever spring. The adjuster
lever on the 13 inch brake, is also equipped with a
lever and tension spring.
The adjuster mechanism performs two important
functions. First, is in maintaining proper brakeshoe
operating clearance. And second, is to maintain brake
pedal height. The mechanism does so, by adjusting
the shoes In small increments to compensate for lin
ing wear. The adjustment process is continuous
throughout the useful life of the brakelining.
The adjuster components are all connected to the
Fig. 8 Lining Wear Compensation By Piston Seal
secondary brakeshoes. Actual adjustment only occurs
DRUM BRAKES during reverse brake stops. Secondary brakeshoe
All BR models are 'equipped with rear drum brake movement (during reverse stops), is what activates
assemblies. They are two-shoe, duo-servo units with the adjuster components.
an automatic adjuster mechanism. In operation, secondary shoe movement causes the
Three different size drum brake assemblies are adjuster lever spring to exert pull on the lever. This
used: pivots the lever away from the adjuster screw teeth.
• 1/2 ton (1500) models: 11 x 2 in. When the stop is completed and the brakes released,
• 3/4 ton (2500) models: 13 x 2.5 In. the adjuster lever pivots back to a normal position. I t
• 1 ton (3500) models: 13 x 3.5 in. is during this return movement of the lever when
Two different wheel cylinders are used. The differ adjustment occurs. At this point, the lever comes
ence being cylinder bore size. The cylinders used on back into contact with the adjuster screw teeth as i t
1/2 and 3/4 ton models have a' bore diameter of 23.8 moves upward. The lever will then rotate the
mm (0.937 or 15/16 in.). The cylinders used on 1 ton adjuster screw one or two teeth as needed for adjust-'
models have a bore diameter of 27 mm (1.06 or ment.
1-1/16 In.).
The drum brakes are a semi-floating, self-energiz NOTE: The adjustment process requires a complete
ing, servo action design. The brakeshoes are not fixed stop to actually occur. Rolling stops will NOT acti
on the support plate. This type of brake allows the vate the adjuster components. In addition, the
shoes to pivot and move vertically to a certain extent. adjuster screws are left and right hand parts and
In operation, fluid apply pressure causes the wheel must NOT be interchanged.
cylinder pistons to move outward. This movement is
transferred directly to the brakeshoes by the cylinder
connecting links. The resulting brakeshoe expansion PARKING BRAKES
brings the lining material Into contact with the rotat The parking brakes are operated by a system of
ing brake drum. cables and levers attached to the rear brake second
Two forces affect the brakeshoes once they contact ary shoes.
the drum. The first force being hydraulic pressure The rear drum brakeshoes serve as the parking
exerted through the wheel cylinder pistons. And the brakes. The shoes make contact with the brake drum
second force is the friction generated turning torque surface by a cable and lever mechanism attached to
of the rotating drum. the secondary brakeshoe. A strut installed • between
The drum forces both brakeshoes to move in the the' primary and secondary shoes maintains- shoe
same direction of rotation. Servo action begins with position when the parking brakes are applied.
the primary brakeshoe which begins to wedge (or The front parking brake cable is connected to the
wrap) Itself against the rotating drum surface. This parking brake pedal and to an intermediate cable.
force is transmitted equally to the secondary brake- The intermediate cable connects the front cable to
shoe through the adjuster screw and anchor pin. The the rear cables.
net result is that each shoe helps the other exert The parking brake pedal assembly is mounted on
extra force against the drum. I t is servo action that the driver side cowl panel. The front cable is directly
creates the wedging (or wrap) effect which produces attached to the assembly. The pedal assembly con
increased force on the drum braking surface. tains a spring loaded, ratchet-type mechanism to
All drum brake assemblies are equipped with a self hold the pedal i n the applied position. A cable and
adjusting mechanism. The components forming the spring are used to release the ratchet mechanism
mechanism consist of the: adjuster screw, adjuster and return the pedal to normal position.
5 -8 BRAKES BR
DESCRIPTION AND OPERATION ( C o n t i n u e d )
BRAKE HOSES AND LINES ROAD TESTING

Flexible rubber hose is used at both front brakes (1) I f complaint involved low brake pedal, pump
and at the rear axle junction block. Double walled pedal and note i f i t comes back up to normal height.
steel tubing is used to connect the master cylinder to (2) Check brake pedal response with transmission
the major hydraulic braking components and then to in Neutral and engine running. Pedal should remain
the flexible rubber hoses. firm under constant foot pressure.
(3) During road test, make normal and firm brake
stops in 25-40 mph range. Note faulty brake opera
DIAGNOSIS AND TESTING tion such as low pedal, hard pedal, fade, pedal pulsa
tion, pull, grab, drag, noise, etc.
BASE BRAKE SYSTEM
Base brake components consist of the brakeshoes, PEDAL FALLS AWAY
calipers, wheel cylinders, brake drums, rotors, brake- A brake pedal that falls away under steady foot
lines, master cylinder, booster, and parking brake pressure is generally the result of a system leak. The
components. leak point could be at a brakeline, fitting, hose, or
Brake diagnosis involves determining i f the prob caliper/wheel cylinder. Internal leakage i n the master
lem is related to a mechanical, hydraulic, or vacuum cylinder caused by worn or damaged piston cups,
operated component. may also be the problem cause.
The first diagnosis step is the preliminary check. If leakage is severe, fluid will be evident at or
around the leaking component. However, internal
PRELIMINARY BRAKE CHECK leakage in the master cylinder may not be physically
(1) Check condition of tires and wheels. Damaged evident.
wheels and worn,, damaged, or underinflated tires
can cause pull, shudder, vibration, and a condition LOW-PEDAL
similar to grab. I f a low pedal is experienced, pump the pedal sev
(2) I f complaint was based on noise when braking, eral times. I f the pedal comes back up, worn lining,
check suspension components. Jounce front and rear rotors, or drums are the most likely causes.
of vehicle and listen for noise that might be caused •
by loose, worn or damaged suspension or steering SP010Y PEDAL
components. A spongy pedal is most often caused by air in the
(3) Inspect brake fluid level and condition. Note system. However, thin brake drums or substandard
that the front disc brake reservoir fluid level will brake lines and hoses can also cause a spongy pedal.
decrease in proportion to normal lining wear. Also The proper course of action is to bleed the system, or
mote that brake fluid tends to darken over time. replace thin drums and suspect quality brake lines
This is n o r m a l and should not be mistaken for and hoses.
contamination.
(a) I f fluid level is abnormally low, look for evi HARD PEDAL OR HIGH PEDAL EFFORT
dence of leaks. at calipers, wheel cylinders, brake- A hard pedal or high pedal effort may be due to
lines, and master cylinder. lining that is water soaked, contaminated, glazed, or
(b) I f fluid appears contaminated, drain out a badly worn. The power booster or check valve could
sample. System will have to be flushed i f fluid is also be faulty.
separated into layers,, or contains a substance
• other than brake fluid. The system seals and cups PEDAL PtJLSAIIOl
will also have to be replaced after flushing. Use Pedal pulsation is caused by components that are
clean brake fluid to flush the system. loose, or beyond tolerance limits.
(4) Check parking brake operation. Verify free The primary cause of pulsation are disc brake
movement and full release of cables and pedal. Also rotors with excessive lateral runout or thickness vari
note If vehicle was being operated with parking ation, or out of round brake drums. Other causes are
brake partially applied. loose wheel bearings or calipers and worn, damaged
(5) Check brake pedal operation. Verify that pedal tires.
does not bind and has adequate free play. I f pedal
lacks free play, check pedal and power* booster for NOTE: Some pedal pulsation may be felt during
being loose or for bind condition. Do not road test RWAL/ABS activation.
until condition is corrected.
(6) I f components checked appear OK, road test
the vehicle.
BR BRAKES I -1

BRAKE DRAG A common and frequently misdiagnosed pull condi
Brake drag occurs when the lining is in constant tion is where direction of pull changes after a few
contact with the rotor or drum. Drag can occur at one stops. The cause is a combination of brake drag fol
wheel, all wheels, fronts only, or rears only. lowed by fade at one of the brake units.
Drag Is a product of incomplete brakeshoe release. As the dragging brake overheats, efficiency is so
Drag can be minor or severe enough to overheat the reduced that fade occurs. Since the opposite brake
linings, rotors and drums. unit is still functioning normally, Its braking effect is
Minor drag will usually cause slight surface char magnified. This causes pull to switch direction in
ring of the lining. I t can also generate hard spots In favor of the normally functioning brake unit.
rotors and drums from the overheat-cool down pro An additional point when diagnosing a change in
cess. In most cases, the rotors, drums, wheels and pull condition concerns brake cool down. Remember
tires are quite warm to the touch after the vehicle is that pull will return to the original direction, I f the
stopped. dragging brake unit is allowed to cool down (and is
Severe drag can char the brake lining all the way not seriously damaged).
through. I t can also distort and score rotors and
drums to the point of replacement. The wheels, tires REAR BRAKE GRAB OR PULL
and brake components will be extremely hot. I n Rear grab or pull is usually caused by improperly
severe cases, the lining may generate smoke as i t adjusted or seized parking brake cables, contami
chars from overheating. nated lining, bent or binding shoes and support
Common causes of brake drag are: plates, or Improperly assembled components. This is
• Seized or improperly adjusted parking brake particularly true when only one rear wheel is
cables. involved. However, when both rear wheels are
• Loose/worn wheel bearing. affected, the master cylinder, proportioning valve, or
• Seized caliper or wheel cylinder piston. RWAL valve could be at fault.
• Caliper binding on corroded bushings or rusted
slide surfaces. BRAKES DO NOT HOLD AFTER DRiWING THROUGH DEEP
WATER PUDDLES
• Loose caliper mounting bracket.
• Drum brakeshoes binding on worn/damaged sup This condition is generally caused by water soaked
port plates. lining. I f the lining is only wet, i t can be dried by
• • Misassembled components. driving with the brakes very lightly applied for a
I f brake drag occurs at all wheels, the problem mile or two. However, if the lining Is both soaked and
may be related to a blocked master cylinder return dirt contaminated, cleaning and/or replacement will
be necessary.
port,' or faulty power booster (binds-does not release).
BRAKE SQUEAK/SQUEAL
BRAKE FADE
Brake fade is usually a - product of overheating Brake squeak or squeal may be due to linings that
caused by brake drag. However, brake overheating are wet or contaminated with brake fluid, grease, or
and resulting fade can also be caused by riding the oil. Glazed linings and rotors with hard spots can
brake pedal, making repeated high deceleration stops also contribute to squeak. Dirt and foreign material
in a short time span, or constant braking on steep embedded in the brake lining will also cause squeak/
mountain roads. Refer to the Brake Drag information squeal.
In this section for causes. A very loud squeak or squeal Is frequently a sign of
severely worn brake lining. I f the lining has worn
BRAKE PULL through to the brakeshoes i n spots, metal-to-metal
Front brake pull condition could result from: contact occurs. I f the condition is allowed to continue,
• Contaminated lining in one caliper rotors and drums can become so scored that replace
® Seized caliper piston ment is necessary.
• Binding caliper
BRAKE CHATTER
• Loose caliper
• Rusty adapter/caliper slide surfaces Brake chatter is usually caused by loose or worn
• Improper brakeshoes components, or glazed/burnt lining. Rotors with hard
• Damaged rotor spots can also contribute to chatter. Additional causes
A worn, damaged wheel bearing or suspension of chatter are out-of-tolerance rotors, brake lining not
component are further causes of pull. A damaged securely attached to the shoes, loose wheel bearings
front tire (bruised, ply separation) can also cause and contaminated brake lining.
pull.
5 -10 BRAKES BR
THUMP/CLUNK NOISE TERMINAL
PINS
Thumping or clunk noises during braking are fre
quently not caused by brake components. In many
cases, such noises are caused by loose or damaged
steering, suspension, or engine components. However,
calipers that bind on the slide surfaces can generate
a thump or clunk noise. In addition, worn out,
Improperly adjusted, or improperly assembled rear
brakeshoes can also produce a thump noise.
BRAKELINING C01TA1I1ATI0I
Brakelining contamination is mostly a product of
leaking calipers or wheel cylinders, worn seals, driv
ing through deep water puddles, or lining that has
become covered with grease and grit during repair. J9405-88
Contaminated lining should be replaced to avoid fur
ther brake problems. Fig. 9 Stoplamp Switch Terminal Identification
WHEEL AND TIRE PROBLEMS

(2) Check continuity between terminal pins 1 and
2 and pins 3 and 4 as follows:
Some conditions attributed to brake components
(a) Push switch plunger inward to fully
may actually be caused by a wheel or tire problem.
retracted position.
A damaged wheel can cause shudder, vibration and
(b) Attach test leads to pins 1 and 2 and note
pull. A worn or damaged tire can also cause pull.
ohmmeter reading.
Severely worn tires with very little tread left can
(c) I f continuity exists, switch is OK. Replace
produce a grab-like condition as the tire loses and
switch i f meter indicates lack of continuity (switch
recovers traction. Flat-spotted tires can cause vibra
is open).
tion and generate shudder during brake operation. A
tire with internal damage such as a severe bruise,
RED BRAKE WARNING LAMP
cut, or ply separation can cause pull and vibration.
The red warning lamp is in circuit with the park
ing brake switch and pressure differential switch in
STOP LAMP SWITCH
the combination valve. On diesel models, the lamp is
Stoplamp switch operation can be tested with an
also in circuit with the low vacuum switch.
ohmmeter. The ohmmeter is used to check continuity
The red lamp illuminates when the parking brakes
between the pin terminals at different plunger posi
are applied, or when a pressure drop occurs in the
tions (Fig. 9).
front or rear brake hydraulic circuit.
NOTE; The switch wire harness must be discon The lamp illuminates for approximately 2-4 sec
nected before testing switch continuity. onds at every engine start up. This is a self test fea
ture designed to check bulb and circuit operation.
A pressure drop in the front or rear brake hydrau
SWITCH CIRCUIT IDENTIFICATION lic circuit activates the pressure differential valve
• terminals 1 and 2 are for the RWAL/ABS module inside the combination valve. A pressure decrease
and Powertrain Control Module (PCM) circuit moves the valve toward the low pressure side. As the
• terminals 5 and 6 are for the stoplamp circuit valve moves, i t pushes the pressure differential
• terminals 3 and 4 are for the speed control cir switch contact plunger upward. This closes the
cuit switch internal contacts and completes the circuit to
the red warning lamp. The lamp will remain on until
SWITCH CONTINUITY TEST repairs are made and normal fluid pressure restored.
(1) Check continuity between terminal pins 5 and
6 as follows: LOW VACUUM SWITCH—DIESEL MODELS
(a) Pull plunger all the way out to fully extended On diesel models, the red brake warning lamp is
position. also used to alert the driver of a low brake booster
(b) Attach test leads to pins 5 and 6 and note vacuum condition. The warning lamp is in circuit
ohmmeter reading. with a vacuum warning switch mounted on the
(c) I f continuity exists, proceed to next test. driver side fender panel. The vacuum side of the
Replace switch i f meter indicates lack of continuity switch is connected to the power brake booster. The
(shorted or open).
BR BRAKES 5 - 11

electrical side of the switch is connected to the red SHORT
brake warning lamp. CONNECTING CHECK
HOSE VALVE
The low vacuum switch monitors booster vacuum
level whenever the engine Is running. I f booster vac
uum falls below 8.5 Inches for a minimum of 10 sec
onds, the switch completes the circuit to the warning
lamp. The warning lamp is designed to differentiate
between a low vacuum condition and a hydraulic cir
cuit fault.
MASTER CYLINDER/POWER BOOSTER

(1) Start engine and check booster vacuum hose
connections. A hissing noise indicates vacuum leak.
Correct any vacuum leak before proceeding.
(2) Stop engine and shift transmission into Neu
tral.
(3) Pump brake pedal until all vacuum reserve in
booster is depleted.
(4) Press and hold brake pedal under light foot VACUUM
GAUGE
pressure. The pedal should hold firm, i f the pedal
falls away master cylinder is faulty (Internal leak J9005-81
age).
Fig. 10 Typical Booster Vacuum Test Connections
(5) Start engine and note pedal action i t .should
falls away slightly under light foot pressure then (4) Apply 15-20 inches vacuum at large end of
holds firm. I f no pedal action is discernible, power check valve (Fig. 11).
booster, vacuum supply, or vacuum check valve is (5) Vacuum should hold steady. I f gauge on pump
faulty. Proceed to the POWER BOOSTER VACUUM Indicates vacuum loss, check valve is faulty and
TEST. should be replaced.
(6) I f the POWER BOOSTER VACUUM TEST
passes, rebuild booster vacuum reserve as follows: BOOSTER
Release brake pedal. Increase engine speed to 1500 CHECK VALVE APPLY T E S T
rpm, close the throttle and Immediately stop turn off
ignition to stop engine.
(7) Wait a minimum of 90 seconds and try brake
action again. Booster should provide two or more vac
uum assisted pedal applications. I f vacuum assist Is
not provided, booster is faulty.
POWER BOOSTER VACUUM TEST

(1) Connect vacuum gauge to booster check valve
with short length of hose and T-fitting (Fig. 10).
(2) Start and run engine at curb idle speed for one
minute.
80316866
(3) Observe the vacuum supply. I f vacuum supply
is not adequate, repair vacuum supply.
Fig. 11 Vacuum Check Valve And Seal
(4) Clamp hose shut between vacuum source and
check valve. DIESEL ENGINE VACUUM PUMP OUTPUT
(5) Stop engine and observe vacuum gauge. Vacuum pump diagnosis involves checking pump
(6) I f vacuum drops more than one inch HG (33 output with a vacuum gauge. The low vacuum warn
millibars) within 15 seconds, booster diaphragm or ing switch can also be checked with a vacuum gauge.
check valve Is faulty. A standard vacuum gauge can be used to check
pump output when necessary. Simply disconnect the
POWER BOOSTER CHECK VALVE TEST pump supply hose and connect a vacuum gauge to
(1) Disconnect vacuum hose from check valve. the outlet port for testing purposes. Vacuum should
(2) Remove check valve and valve seal from hold steady in a range of approximately 8.5 to 25
booster. inches at various engine speeds.
(3) Use a hand operated vacuum pump for test.
5 - 12 BRAKES BR

DIAGNOSING LOW VACUUM OUTPUT (3) Connect bleed hose to a rear wheel cylinder
CONDITION and immerse hose end in container partially filled
A low booster vacuum condition or a faulty low with brake fluid.
vacuum warning switch will cause the brake warning (4) Have helper press and hold brake pedal to floor
lamp to illuminate. I f the lamp does go on and indi and observe warning light.
cates the existence of a low vacuum condition, check (a) I f warning light illuminates, switch is operat
the vacuum pump, booster and warning switch as fol ing correctly.
lows: (b) I f light fails to illuminate, check circuit fuse,
(1) Check vacuum pump oil feed line. Verify that bulb, and wiring. The parking brake switch can be
line connections are secure and not leaking. I f leak used to aid i n identifying whether or not the brake
age is noted and pump is noisy, replace pump. light bulb and fuse is functional. Repair or replace
(2) Disconnect supply hose to booster. Connect vac - parts as necessary and test differential pressure
uum gauge to this hose and run engine at various switch operation again.
throttle openings. Output should range from 8.5 to (5) I f warning light still does not illuminate,
25 inches vacuum. I f vacuum is consistently below switch is faulty. Replace combination valve assembly,
8.5 inches, problem is with vacuum hoses or pump bleed brake system and verify proper switch and
component. I f output is within specified limits, con valve operation.
tinue testing.
(3) Check booster operation as described In diagno DISC BRAKE ROTOR
sis section. Replace check valve, vacuum hoses, or The rotor braking surfaces should not be refinished
booster i f necessary. However, i f booster operation is unless necessary.
correct but warning lamp is still on, continue testing. Light surface rust and scale can be removed with a
(4) Disconnect vacuum hose at warning switch. lathe equipped with dual sanding discs. The rotor
Plug hose and connect hand vacuum pump to switch. surfaces can be restored by machining i n a disc brake
(5) Start and run engine. lathe i f surface scoring and wear are light.
(6) Apply 8.5 to 9 Inches of vacuum to warning Replace the rotor under the following conditions:
switch and observe warning lamp. I f lamp goes out, • severely scored
switch vacuum hose Is either loose or leaking. I f • tapered
lamp remains on, leave engine running and continue • hard spots
testing. • cracked
(7) Apply 20-25 inches vacuum to switch and • below minimum thickness
observe warning lamp operation. I f lamp now goes
out, switch is at fault and should be replaced. I f lamp ROTOR MINIMUM THICKNESS
remains on, continue. testing. Measure rotor thickness at the center of the brake-
(8) * Connect vacuum hoses and replace original shoe contact surface. Replace the rotor i f worn below
warning switch with known good switch. Run engine minimum thickness, or i f machining would reduce
and observe warning lamp operation. I f lamp is now thickness below the allowable minimum.
off, old switch is faulty, i f lamp remains on, problem Rotor minimum thickness is usually specified on
is in wiring between switch and warning lamp. the rotor hub. The specification is either stamped or
cast into the hub surface.
COMBINATION VALVE
ROTOR RUNOUT
Metering Valve Check rotor lateral runout with dial indicator
Metering valve operation can be checked visually C-3339 (Fig. 12). Excessive lateral runout will cause
and with the aid of a helper. Observe the metering brake pedal pulsation and rapid, uneven wear of the
valve stem while a helper applies and releases the brakeshoes. Position the dial indicator plunger
brakes. I f the valve is operating correctly, the stem approximately 25.4 mm (1 in.) inward from the rotor
will extend slightly when the brakes are applied and edge.
retract when the brakes are released. I f the valve is
faulty, replace the entire combination valve as an NOTE: Be sure wheel bearing has zero end play
assembly. before checking rotor runout.
Pressure Differential Switch

(1) Have helper sit in drivers seat to apply brake
pedal and observe red brake warning light.
(2) Raise vehicle on hoist.
BR BRAKES 5 • 13

Maximum allowable rotor runout is 0.127 mm outer edge. Generally, a drum can be machined to a
(0.005 in.). maximum of 1.52 mm (0.060 in.) oversize. Always
replace the drum i f machining would cause drum
diameter to exceed the size limit indicated on the
drum.
BRAKE DRUM RUNOUT

Measure drum diameter and runout with an accu
rate gauge. The most accurate method of measure
ment involves mounting the drum in a brake lathe
and checking variation and runout with a dial Indi
cator.
Variations in drum diameter should not exceed
0.076 mm (0.003 in.). Drum runout should not exceed
0.20 mm (0.008 in.) out of round. Machine the drum
if runout or variation exceed these values. Replace
the drum i f machining causes the drum to exceed the
DIAL
maximum allowable diameter.
INDICATOR
J8905-68
BRAKE LINE AND HOSES
Flexible rubber hose is used at both front brakes
Fig. 12 Checking Rotor Runout And Thickness
and at the rear axle junction block. Inspect the hoses
Variation
whenever the brake system is serviced, at every
MOTOR THICKNESS VARIATION engine oil change, or whenever the vehicle is in for
Variations in rotor thickness will cause pedal pul service.
sation, noise and shudder. Inspect the hoses for surface cracking, scuffing, or
Measure rotor thickness at 6-to-12 points around worn spots. Replace any brake hose immediately i f
the rotor face (Fig. 13). the fabric casing of the hose is exposed due to cracks
Position the micrometer approximately 25.4 mm ( 1 or abrasions.
in.) from the rotor outer circumference for each mea Also check brake hose'installation. Faulty installa
surement. tion can result in kinked, twisted hoses, or contact
Thickness should not vary by more than 0.025 mm with the wheels and tires or other chassis compo
(0.001 in.) from point-to-point on the rotor. Machine nents. A l l of these condition can lead to scuffing,
or replace the rotor If necessary. cracking and eventual failure.
The steel brake lines should' be inspected periodi
cally for evidence of corrosion, twists, kinks, leaks, or
MICROMETER other damage. Heavily corroded lines will eventually
rust through causing leaks. I n any case, corroded or
damaged brake lines should be replaced.
Factory replacement brake lines and hoses are rec
ommended to ensure quality, correct length and supe
rior fatigue life. Care should be taken to make sure
that brake line and hose mating surfaces are clean
TAKE MINIMUM and free from nicks and burrs. Also remember that
ROTOR
OF 6 MEASUREMENTS right and left brake hoses are not interchangeable.
AROUND ROTOR
Use new copper seal washers at all caliper connec
tions. Be sure brake line connections are properly
made (not cross threaded) and tightened to recom
mended torque.
J9405-103
BRAKE FLUID CONTAMINATION

Indications of fluid contamination are swollen or
Fig. 13 Measuring Rotor Thickness deteriorated rubber parts.
Swollen rubber parts Indicate the presence of
BRAKE DRUi petroleum in the brake fluid.
The maximum allowable diameter of the drum To test for contamination, put a small amount of
braking surface is stamped or cast into the drum drained brake fluid i n clear glass jar. I f fluid sepa-
5 - 14 BRAKES BR

rates into layers, there is mineral oil or other fluid INDICATOR
contamination of the brake fluid. WINDOW
If brake fluid is contaminated, drain and thor
oughly flush system. Replace master cylinder, propor
tioning valve, caliper seals, wheel cylinder seals, CORRECT
Antilock Brakes hydraulic unit and all hydraulic FLUID
LEVEL
fluid hoses. (TO TOP
OF WINDOW)
SERVICE PROCEDURES
BRAKE FLUID LEVEL

Correct fluid level is to the top of the oval Indicator
window on the side of the reservoir (Fig. 14) and
(Fig. 15). An acceptable level is between the top of
the indicator window and the M1N mark. The
hydraulic system -should be checked for leaks,
or the brakeshoes for excessive wear, if fluid
level is very near the MIN level.
Always clean the master cylinder reservoir and
cover before removing the cover to add fluid. I f this is J9405-23
not done, dirt from the cover or reservoir could enter
the fluid. Fig. 14 Fiuid Level Indicator (Model 1500 & 2500)
Add fluid to the correct level i f necessary. Note
that fluid level in the reservoirs will decrease slightly
in proportion to lining wear. This is a normal condi CORRECT
tion. I f fluid is needed, use Mopar brake fluid or an FLUID
1
LEVEL
equivalent meeting SAE standard J1703 and Federal [TO TOP OF r 1
i
standard DOT 3. -INDICATOR
Check the cover diaphragm seal and replace i t i f WINDOWS)
torn or distorted. Snap the seal into place before

installing the cover.
CAUTION: Verify that the diaphragm seal is firmly

seated in the reservoir cover. If the seal is improp
erly seated, it will shift out of position when the
cover is installed resulting in fluid leakage and
eventual contamination.
1ASTER CYLINDER'BLEEDING
An overhauled, or new master cylinder should
always be bled before installation i n the vehicle. This
practice saves time during brake bleeding because air
in the cylinder will not be pumped into the lines. J9405-24
' The only tools needed for bench bleeding are a
vise, a pair of bleed tubes, and a length of wood Fig. 15 Fluid Level Indicators (Model 3500)
dowel. Bleed tubes can either be purchased or fabri (4) Bleed cylinder by stroking cylinder pistons
cated from spare brake lines and fittings. inward then allowing them to return under spring
(1) Mount master cylinder in vise. Clamp vise jaws pressure. Use a wood dowel, or similar tool to stroke
on one of the cylinder mounting ears. pistons (Fig. 16).
(2) Install bleed tubes in cylinder outlet ports and (5) Continue stroking pistons until bubbles no
direct tube ends into appropriate reservoir chambers longer appear in fluid entering reservoir.
(Fig. 16). (6) Remove bleed tubes and install plastic plugs in
(3) Fill reservoir chambers about 3/4 full with cylinder outlet ports. Plugs will prevent fluid loss
fresh, clean brake fluid. and keep dirt out until cylinder assembly is ready for
installation.
BR BRAKES 5 - 15
SERVICE' PROCEDURES (Continued)

WOOD
(3) Attach one end of bleed hose to bleed screw
and insert opposite end in glass container partially
filled with brake fluid (Fig. 17). Be sure end of bleed
hose is immersed in fluid.
FLUID) J9405-71
Fig. 16 Master Cylinder Bleeding

(7) Top off reservoir fluid level and install cover
and seal.
CAUTION: Be sure the seal is properly positioned

on the reservoir cover. The seal can shift .out of
position during installation if care is not exercised.
J8905-18
This will result in leakage and possible fluid con
tamination.
Fig. 17 Typical Fluid Container And Bleed Hose
Setup
BRAKE BLEEPING (4) Open up bleeder, then have a helper press
Use Mopar brake fluid, or an equivalent quality down the brake pedal. Once the pedal Is down close
fluid meeting SAE J1703-F and DOT 3 standards the bleeder.. Repeat bleeding until fluid stream is
only. Use fresh, clean fluid from a sealed container at clear and free of bubbles. Then move to the next
all times. wheel.
Do not pump the brake pedal at any time while
bleeding. Air in the system - will be compressed into DiSC ROTOR MACHINING
small bubbles that are distributed throughout the Rotor braking surfaces can be sanded or machining
hydraulic system. This will make additional bleeding in a disc brake lathe.
operations necessary. The lathe must machine both sides of the rotor
Do not allow the master cylinder to run out of fluid simultaneously with dual (two) cutter heads (Fig.
during bleed operations. An empty cylinder will allow 18). Equipment capable of machining only one side at
additional air to be drawn into the system. Check the a time will produce. a tapered rotor.
cylinder fluid level frequently and add fluid as The lathe should also be equipped with a grinder
needed. attachment or dual sanding discs for final cleanup or
The Brakes should be bled In sequence. First the light refinishing (Fig. 18).
right rear wheel then the left rear wheel. Then move If the rotor surfaces only need minor cleanup of
to the front brakes and bleed the right front wheel rust, scale, or minor scoring, use abrasive discs to
then the left front wheel. clean up the rotor surfaces. However, when a rotor is
scored or worn, machining with cutting tools will be
MANUAL BLEEDING required.
(1) Remove reservoir filler caps and fill reservoir
with Mopar, or equivalent quality DOT 3 brake fluid. CAUTION: Do not machine the rotor if it will cause
(2) I f calipers, or wheel cylinders were overhauled, the rotor to fall below .minimum allowable thick
open all caliper and wheel cylinder bleed screws. ness.
Then close each bleed screw as fluid starts to drip
from it. Top off master cylinder reservoir once more
before proceeding.
5 - 16 BRAKES BR
always be used around the drum to reduce vibration
and avoid chatter marks.
The maximum allowable diameter of the drum
braking surface Is stamped or cast into the drum,
outer edge. Always replace the drum i f machining
would cause drum diameter to exceed the size limit
indicated on the drum.
BRAKE LINE
Mopar preformed metal brake line is recommended
and preferred for all repairs. However, double-wall
steel line can be used for emergency repair when fac
tory replacement parts are not readily available.
Special, heavy duty tube bending and flaring
equipment is required to prepare double wall brake
line. Special bending tools are needed to avoid kink
ing or twisting metal brake line. I n addition, special
flaring tools are needed to provide the Inverted-type,
double flare required on metal brake lines.
FLARING PROCEDURE
(1) Cut off damaged tube with Tubing Cutter.
(2) Ream cut edges of tubing to ensure proper
flare.
(3) Install replacement tube nut on section of tube
to be repaired.
(4) Insert tube In flaring tool. Center tube in area
between vertical posts.
(5) Place gauge form over the end of the tube.
(6) Push tubing through flaring tool jaws until
tube contacts recessed notch In gauge that matches
tube diameter.
(7) Squeeze flaring tool jaws to lock tubing in
place.
(8) insert plug on gauge in the tube. Then swing
compression disc over gauge and center tapered flar
ing screw In recess of compression disc (Fig. 19).
(9) Tighten tool handle until plug gauge is seated
on jaws of flaring tool. This will start the inverted
flare.
(10) Remove the plug gauge and complete the
inverted flare.
(11) Remove the flaring tools and verify that the
J8905-70
inverted flare is correct.
Fig. 18 Rotor Refinishing
BRAKE DRUM MACHINING REMOVAL AND INSTALLATION
The brake drums can be machined on a drum lathe
STOP LAMP SWITCH
when necessary. Initial machining cuts should be lim
ited to 0.12 - 0.20 mm (0.005 - 0.008 in.) at a time as
REMOVAL
heavier feed rates can produce taper and surface
(1) Remove knee bolster for access to stop lamp
variation. Final finish cuts of 0.025 to 0.038 mm
switch and pedal.
(0.001 to 0.0015 in.) are recommended and will gen
(2) Disconnect switch harness (Fig. 20).
erally provide the best surface finish.
(3) Press and hold brake pedal in applied position.
Be sure the drum is securely mounted in the lathe
(4) Rotate switch counterclockwise about 30° to
before machining operations. A damper strap should
align switch lock tab with notch in bracket.
BR BRAKES 5 - 17
R E M O V A L A N P I N S T A L L A T I O N (Continued)
TAB N O T C H
( I N BRACKET)
J9505-141
Fig. 21 Stop Lamp Switch

(6) Release brake pedal. Then lightly pull pedal
fully rearward. Pedal will adjust switch plunger to
RH222 correct position as pedal is moved to rear.
Fig. 19 inverted Flare Tools CAUTION: Do not use excessive force to move the
pedal rearward for switch adjustment. Excessive
(5) Pull switch rearward out of mounting bracket force will damage the switch.
and release brake pedal.
SWITCH
BRACKET
BRAKE PEDAL
REMOVAL
(1) Remove knee bolster.
(2) Remove stop lamp switch.
(3) Remove switches from tabs on stop lamp
switch bracket.
(4) Remove stop lamp switch bracket bolts and
remove bracket (Fig. 22).
BRAKE LIGHT
SWITCH
HARNESS
CONNECTOR J9505-139
Fig. 20 Stop Lamp Switch & Harness Connector

INSTALLATION
(1) Pull switch plunger all the way out to fully
extended position.
(2) Push switch plunger inward 4 detent positions BRAKELIGHT
(or clicks). This is required preset position for switch D C N A I SWITCH
installation. Plunger will extend approximately 14 BRACKET B R A C K E T
mm (0.55 in.) out of housing at this setting. BRACKET

S C R E W S (2) J9505-140
(3) Connect harness wires to switch.
(4) Press and hold brake pedal down.
Fig. 22 Brake Lamp Switch Bracket
(5) Install switch. Align tab on switch with notch
in switch bracket (Fig. 21). Then insert switch in (5) Remove clip and washer attaching booster push
bracket and turn i t clockwise about 30° to lock i t in rod and slide push rod off pedal.
place.
5-18 BRAKES mm
(6) Remove E-clip from passenger side of pedal RWAL VALVE/COMBINATION VALVE
shaft (Fig. 23). Use flat blade screwdriver to pry clip
out of shaft groove. REMOVAL
(7) Push shaft toward driver side of bracket just (1) Disconnect ground wire and harness wires from
enough to expose opposite E-clip. Then remove E-clip combination valve switch and RWAL valve (Fig. 24).
with flat blade screwdriver.
(8) Push pedal shaft back and out of passenger
side of bracket (Fig. 23).
(9) Remove brake pedal and pedal shaft from vehi
cle.
PEDAL SHAFT
Fig. 24 Valve Harness

(2) Disconnect lines to front and rear brakes from
RWAL and combination valves (Fig. 25).
Fig. 23 Brake Pedal Mounting (With Automatic

Transmission)
INSTALLATION
(1) Replace bracket and pedal bushings i f neces
sary. Lubricate shaft bores in bracket and pedal
before installing bushings with Mopar Multi-mileage
silicone grease.
(2) Apply liberal quantity of Mopar multi-mileage
grease to pedal shaft and to pedal and bracket bush
ings.
(3) Position brake pedal in mounting bracket.
(4) Slide pedal shaft into bracket and through
FRONT
pedal from passenger side. BRAKES J9405-82
(5) Push pedal shaft out driver side of mounting
bracket just enough to allow Installation of retaining
Fig. 25 Master Cylinder brake lines
E-clip.
(6) Push pedal shaft back toward passenger side of (3) Remove brake lines connecting master cylinder
bracket and install remaining E-clip on pedal shaft. to combination valve.
(7) Install booster push rod on brake pedal. Secure (4) Remove nuts attaching master cylinder and
push rod to pedal with washer and retaining clip. combination valve bracket to booster studs.
(8) Install stop lamp switch bracket and switch. (5) Remove master cylinder.
(9) Install knee bolster. (6) Remove combination valve, valve bracket and
RWAL valve as assembly.
BR BRAKES 5-19
R E M O V A L AND I N S T A L L A T I O N {Continued)
(7) Remove brake line connecting combination aged if care is not exercised. Use a flare nut
valve to RWAL valve. wrench to loosen or tighten the fittings and
(8) Remove bolt attaching RWAL valve to combina start all brake line fittings by hand to avoid
tion valve bracket (Fig. 26). Then separate RWAL cross threading.
valve from bracket.
REMOVAL
(1) Remove brake lines connecting master cylinder
to combination valve (Fig. 27).
Fig. 26 RWAL Valve/Combination Valve

INSTALLATION
(1) Install RWAL valve on combination valve Fig. 27 Combination Valve- To-Mlas ter Cylinder brake
bracket. Do not tighten RWAL valve bolt completely lines
at this time.
(2) Install short brake line that connects RWAL (2) Remove nuts attaching combination valve
valve to combination valve. Tighten line fittings to bracket and master cylinder to brake booster mount
16-23 N-m (140-200 in. lbs.). ing studs.
(3) Tighten RWAL valve attaching bolt to 23-34 (3) Slide combination valve bracket off booster
N-m (200-300 in. lbs.). mounting studs.
(4) Install master cylinder on booster mounting (4) Remove master cylinder.
studs.
INSTALLATION
(5) Attach antilock harness ground wire to combi
nation valve bracket. (1) Position master cylinder on booster mounting
(6) Install combination valve bracket on booster studs. Be sure booster push rod is aligned and seated
mounting studs and against master cylinder. in primary piston.
(7) Loosely install nuts that retain master cylinder (2) Install combination valve bracket on mounting
and combination valve on booster studs. studs. Bracket goes on top of cylinder mounting (Fig.
(8) Install and connect all remaining brake lines. 28).
Tighten line fittings to 16-23 N-m (140-200 in. lbs.). (3) Start all brake line fittings in cylinder and
(9) Connect harness wires to RWAL valve and to valves by hand.
combination valve switch. (4) Install master cylinder attaching nuts on
(10) Fill and bleed brake system. booster studs. Tighten nuts to 23-34 N-m (200-300 in.
lbs.).
MASTER CYLINDER (5) Have an assistant depress the brake pedal
Exercise care when removing/installing the slowly and hold it down.
master cylinder, combination valve and (6) Tighten brake line fittings to 16-23 N-m (140-
antilock valve connecting lines. The threads in 200 in. lbs.).
the cylinder and valve fluid ports can be dam
5 - 20 BRAKES BR
REMOVAL
(1) Disconnect harness wires from differential
switch on combination valve and from RWAL valve.
(2) Disconnect brake line from combination valve
to front brakes, or ABS valve. Then disconnect brake
line from RWAL valve to rear brakes.
(3) Remove nuts attaching master cylinder and
valves to power brake booster studs. Then remove
master cylinder and valves as assembly (Fig. 30).
Fig. 28 Master Cylinder/Combination Valve Bracket

Mounting
MASTER
Fig. 30 Master Cylinder & Valve Assembly
(4) Disconnect vacuum hose at booster check valve.
(5) Remove knee bolster for access to brake pedal.
(6) Remove clip and washer securing booster push
rod to brake pedal and slid rod off pedal (Fig. 31).
BOOSTER WASHER CUP
ABS VALVE SECONDARY LINE J9405-72
Fig. 29 Master Cylinder & Valve brake line

Connections Fig. 31 Booster Push Rod
POWER BRAKE BOOSTER (7) Remove nuts attaching booster mounting studs
The standard and high output boosters are identi to dash panel and pedal mounting bracket and
fied by code letters on the forward face of the booster. remove booster (Fig. 32).
Booster I.D. code letters are:
• 1/2 ton booster code is ZK
• 3/4 and 1 ton booster code is ZL
BR BRAKES 5 - 21
Fig. 32 Booster Mounting

INSTALLATION
NOTE: If new booster is being installed, check

code letters to verify that correct booster is being
installed.
Fig. 33 Vacuum And Steering Pump Hose
(1) Position booster on engine compartment dash Connections
panel.
(2) Install and tighten booster mounting stud nuts
to 23-34 N-m (200-300 in. lbs.).'
(3) Connect booster push rod to brake pedal.
(4) Install knee bolster.
(5) Connect vacuum hose to booster check valve.
(6) Install master cylinder and valves on booster
as assembly and tighten mounting nuts to 23-34 N-m
(200-300 in. lbs.).
(7) Connect front/rear brake lines to combination
valve and RWAL valve. Tighten brake line fittings to
16-23 N-m (140-200 in. lbs.).
(8) Connect harness wires to RWAL valve and
pressure differential switch on combination valve.
(9) Fill and bleed brake system. Refer to proce
dures in appropriate antilock brake section.
POWER BRAKE VACUUM P U i P (DIESEL ENGINE)
REMOVAL PUMP . ENGINE BLOCK J 9 1
(1) Disconnect battery negative cable.

(2) Position drain pan under power steering pump. Fig. 34 Oil Pressure Sender Location
(3) Disconnect vacuum and steering pump hoses
(Fig. 33).
(4) Disconnect oil pressure sender wires and
remove sending unit (Fig. 34).
5 - 22 BRAKES BR

(5) Disconnect lubricating oil feed line from fitting (8) Remove upper bolt that attaches pump assem
at underside of vacuum pump (Fig. 35). bly to engine block (Fig. 37).
(6) Remove lower bolt that attaches pump assem (9) Remove pump assembly from vehicle.
bly to engine block (Fig. 36).
(7) Remove bottom, inboard nut that attaches
adapter to steering pump. This nut secures a small
bracket to engine block. Nut and bracket must be
removed before pump assembly can be removed from
block.
Fig. 37 Pump Assembly Upper Mounting Bolt

(10) Remove nuts attaching vacuum pump to
adapter (Fig. 38).
LINE J9105-96
Fig. 35 Oil Feed Line Connection At Pump

PUMP ASSEMBLY
J9105-98
Fig. 38 Pump Assembly Removal

(11) Remove vacuum pump from adapter (Fig. 39).
Turn pump gear back and forth to disengage pump
shaft from coupling.
(12) Remove coupling from adapter (Fig. 40).
(13) Remove remaining adapter attaching nuts
BOTTOM-INBOARD
and remove adapter from steering pump (Fig. 41). I f
ADAPTER BRACKET NUT J9105-97
steering pump will be serviced, remove spacer from
Fig. 36 Adapter And Pump Mounting Fastener each inboard mounting stud on pump.
Location
ER — - IRMES I - 23
COUPLING
O-RING PUMP
ADAPTER
J9105-99
Fig. 39 Vacuum Pump Removed From Adapter
Fig. 41 Steering Pump Mounting Stud Spacer

Locations
(8) Install and tighten vacuum pump attaching
nuts.
(9) Inspect adapter O-ring and replace O-ring i f
cut or torn.
(10) Lubricate adapter O-ring with engine oil.
(11) Note position of drive slots in coupling (Fig.
42). Then rotate drive gear to align tangs on vacuum
pump shaft with coupling.
ROTATE DRIVE
GEAR TO ALIGN
Fig. 40 Pump Drive Coupling

INSTALLATION
(1) Clean and lubricate pump shaft with engine
oil.
(2) Install spacers on steering pump studs.
(3) Install O-ring on adapter.
(4) Position adapter on pump studs.
(5) Install attaching nuts on outboard stud and on
the two upper pump studs. Do not install nut on
lower, inboard stud at this time. Tighten nuts to 24
N-m (18 ft. lbs.).
(6.) Install coupling on pump shaft. Be sure cou SHAFT
pling is securely engaged in shaft drive tangs. DRIVE
(7) Install vacuum pump on adapter. Rotate drive TANGS J9105-102
gear until tangs on pump shaft engage in coupling.

Fig. 42 Pump Shaft Drive Tangs
Verify that pump is seated before installing attaching
nuts.
5 - 24 BRAKES _ _ _ BR
(12) Verify that pump is seated in adapter and (17) Working from under vehicle, install pump
coupling. assembly lower attaching bolt. Then tighten upper
(13) Install and tighten, pump attaching nuts and and lower bolt to 77 N-m (57 ft. lbs.).
washers. (18) Position bracket on steering pump inboard
(14) Position new gasket on vacuum pump mount stud. Then install remaining adapter attaching nut
ing flange (Fig. 43). Use Mopar Perfect Seal, or sili on stud. Tighten nut to 24 N-m (18 ft. lbs.).
cone adhesive/sealer to hold gasket in place. (19) Connect oil feed line to vacuum pump connec
tor and tighten line fitting.
(20) Install oil pressure sender and connect sender
wires.
(21) Connect steering pump pressure and return
lines to pump. Tighten pressure line fitting to 30
N-m (22 ft. lbs.).
(22) Connect vacuum hose to vacuum pump.
(23) Connect battery cables, i f removed.
(24) Fill power steering pump reservoir.
(25) Purge air from steering pump lines. Start
engine and slowly turn steering wheel left and right
to circulate fluid and purge air from system.
(26) Stop engine and top off power steering reser
voir fluid level.
(27) Start engine and check brake and steering
operation. Verify that power brake booster is provid
ing vacuum assist and firm brake pedal is obtained.
Fig. 43 Pump Mounting Fiange Gasket Then verify that steering action is correct. Do this
(15) Insert pump assembly upper attaching bolt in before moving vehicle.
mounting flange and gasket. Use sealer or grease to
hold bolt in place i f necessary. DISC BRAKE CALIPER
(16) Position pump assembly on engine and install
upper bolt (Fig. 44). Tighten upper bolt only enough REMOVAL
to hold assembly in place at this time. (1) Raise vehicle.
(2) Remove wheel and tire assemblies.
(3) Press caliper piston back into bore with large
flat blade screwdriver (Fig. 45). Use large C-clamp to
bottom piston i n bore i f additional force is required.
Fig. 45 Pressing Caliper Piston Into Bore
Fig. 44 Installing Pump Assembly On Engine

BR BRAKES 5-25
(4) Remove caliper mounting bolts with 3/8 hex
wrench or socket (Fig. 46) and (Fig. 47).
Fig. 46 Caliper Mounting Bolt (1/2 Ton)
J9405-28
Fig. 48 Caliper Removal/lnstallation

seated against locating shoulder on caliper and
hose is not twisted, or kinked before tightening
fitting bolt.
Fig. 47 Caliper Mounting Bolt (3/4 and 1 Ton)

(5) Rotate caliper rearward off rotor and out of
steering knuckle support ledges (Fig. 48).
(6) Remove front brake hose fitting bolt completely
and remove caliper and brakeshoes as assembly.
(7) Cover open end of front brake hose fitting to
prevent dirt entry.
Fig. 49 Front Brake Hose Attachment
INSTALLATION (5) Fill and bleed brake system. Refer to procedure
(1) Clean caliper and steering knuckle slide sur in appropriate antilock brake section.
faces with wire brush. Then apply coat of Mopar (6) Install wheel and tire assemblies and lower
multi-mileage grease, or Dow/GE, silicone grease to vehicle.
slide surfaces.
(2) Install caliper over rotor and seat it on steering DISC BRAKESHOE
knuckle mounting arms.
(3) Start caliper mounting bolts by hand to avoid REMOVAL
cross threading. Then tighten mounting bolts to 51 (1) Raise and support vehicle.
N-m (38 ft.lbs.). (2) Remove wheel and tire assemblies.
(4) Connect brake hose to caliper (Fig. 49) and
(Fig. 50). Inure brake hose fitting is correctly
5 • 26 BRAKES 3R
CONTROL
FRONT HOSE
AND TUBE
ASSEMBLY J9405-51
Fig. 50 Front Brake Hose Routing (4 WD) Fig. 52 Outboard Brakeshoe Removal
(3) Press caliper piston back into bore with large wire to support and secure the caliper to a chassis
flat blade screwdriver. Use large C-clamp If more or suspension component.
force is required to bottom piston in bore.
(4) Loosen bolt that secures front brake hose fit I f the brakeshoes will be reused, do not intermix
ting bolt in caliper. them. Keep the brakeshoes with the caliper they
(5) Remove caliper mounting bolts with 3/8 hex were removed from.
wrench or socket.
(6) Rotate caliper rearward off rotor and out of INSTALLATION
steering knuckle support ledges.
NOTE: Replace riveted lining if worn to within 1.5
(7) Remove inboard and outboard brakeshoes (Fig.
mm (1/16 in.) of rivet heads. Replace bonded lining
51) and (Fig. 52). Inboard shoe has spring clip that
if thickness is 3 mm (3/16 in.) or less.
holds i t in caliper piston. Tilt this shoe out at top to
unseat clip. Outboard shoe has retaining spring that (1) Clean caliper and steering knuckle slide sur
secures i t in caliper. Unseat one spring end and faces with wire brush (Fig. 53). Then apply coat of
rotate shoe out of caliper. Mopar multi-mileage grease to slide surfaces.
INBOARD
J9405-49
Fig. 51 inboard Brakeshoe Removal

Fig. 53 Caliper And Steering Knuckle Slide Surfaces
(8) Secure caliper to convenient chassis or suspen
sion component with wire. (2) Lubricate caliper mounting bolts, collars, bush
ings and bores with Dow 111, or GE 661 silicone
CAUTION: Do not allow the brake hose to support grease as follows:
the caliper. Suspending the caliper by the brake
hose can damage the hose and fitting joints. Use
BR BRAKES 5 - 27
R E M O V A L AND INSTALLATION fContinued)

© 1/2 ton models with 75 mm caliper, apply sili (3) Install inboard brakeshoe in caliper. Be sure
cone grease to mounting pins and collars. Then fill spring clip on shoe is properly aligned and seated in
space between bushings in caliper (Fig. 54). caliper piston (Fig. 56).
• 3/4 and 1 ton models with 80 or 86 mm calipers,
coat mounting pin and interior of bushing with sili CALIPER
cone grease (Fig. 55). PISTON
APPLY SILICONE
GREASE WHERE
INDICATED
CALIPER INBOARD
BOOT
SHOE
J9405-34
MOUNTING
BOLT Fig. 56 Inboard Brakeshoe Installation
SEAL (4) Install outboard brakeshoe in caliper. Be sure
spring ends are seated in dimples in caliper (Fig. 57).
OUTBOARD
BRAKESHOE
BUSHINGS
SPRING
J9405-32 CLIP
INBOARD
Fig. 54 Mounting Bolt Lubrication (75mm Caliper) BRAKESHOE
RETAINING
SPRING
APPLY SILICONE GREASE MOUNTING
WHERE INDICATED BOLT
J9405-29
BUSHING
Fig. 57 Brakeshoe Position In Caliper
(5) Install caliper over rotor and into steering
CALIPER
knuckle mounting arms (Fig. 58). Be sure caliper is
seated flush on mounting arm surfaces as
J9405-33 shown.
(6) Start caliper mounting bolts by hand to avoid
Fig. 55 Mounting Bolt Lubrication (80 or 86mm cross threading. Then tighten mounting bolts to 51
Caliper) N-m (38 ft. lbs.) torque.
(8) Lower vehicle and tighten wheel lug nuts to
following torque:
5 - 28 BRAKES BR
SPLASH
SHIELD
GREASE
SEAL
INNER
BEARING
A N D RACE
ROTOR
OUTER
BEARING
A N D RACE
COTTER
PIN
A N D NUT
CALIPER
/ SLIDE SURFACE J9405-35
Fig, 58 Caliper installation

• 108-150 N-m (80-110 ft. lbs.) on 5 stud wheel WASHER
• 163-203 N-m (120-150 ft. lbs.) on 8 stud single CAP
wheel
(9) Pump brake pedal to reseat caliper pistons and J9405-178
brakeshoes. Do not move vehicle u n t i l shoes
Fig. 59 Rotor And Hub Assembly (With Tapered
have been properly seated.
Bearings)
(10) Check brake fluid level and add fluid i f neces
sary. (2) Apply liberal coat of bearing grease to spindle,
interior of rotor hub, grease seal lip and seal surface
DISC BRAKE ROTOR (WITH TAPERED BEAR110S) of spindle.
(3) Install rotor and hub assembly on spindle.
REMOVAL (4) Install outer wheel bearing thrust washer and
(1) Raise vehicle. bearing adjusting nut. Tighten nut only enough to
(2) Remove wheel and tire assembly. remove end play at this time.
(3) Remove caliper from rotor. (5) Install disc brake caliper. Do not seat caliper
(4) On models with removable adapter hub, pistons at this time. Pistons must not be seated
remove hub from rotor. until after wheel bearing adjustment has been
(5) On models with one-piece rotor and hub assem completed.
bly, remove grease cap that covers cotter pin and hub (6) On models with removable hub adapter install
nut. adapter on rotor.
(6) Remove grease cap from hub. On models with (7) Install wheel and tire assembly. Tighten wheel
long adapter, use long pry tool with angled end to nuts snug but not to final torque at this time.
remove grease cap. Pry against flats at each side of (8) Adjust wheel bearings by rotate wheel and
cap to loosen and remove it. fully tighten bearing adjusting nut to seat bearings.
(7) Remove cotter pin from spindle and wheel Loosen and tighten bearing adjusting nut once again
bearing adjusting nut (Fig. 59). while rotating wheel.
(8) Remove locknut from wheel bearing adjusting (9) Continue rotating wheel and back off adjusting
nut. Then remove thrust washer and outer wheel nut until wheel end play is no more than 0.025 to
bearing. 0.051 mm (0.001 to 0.002 in.).
(9) Remove rotor and hub assembly from spindle. (10) Install nut lock on adjusting nut and install
(10) Inspect wheel bearings and interior of hub. I f new cotter pin. Adjusting nut can be tightened
bearings need repacking, remove grease seal and slightly to align cotter pin holes i f necessary. Verify
inner wheel bearing from rotor hub. that wheel bearing adjustment is still OK.
(11) Install grease cap and wheel cover/hub cap.
INSTALLATION (12) Tighten lug nuts to proper torque.
(1) Repack wheel bearings with Mopar high tem
perature bearing grease. Apply grease to bearing
races as well. Then install inner bearing in hub and
install new grease seal.
BR BRAKES 5 - 29

DISC BRAKE ROTOR (WITH UNIT BEARINGS)
REMOVAL
(1) Raise vehicle.
(8) Remove caliper from rotor.
(4) On 1500 model vehicles remove rotor.
(5) On models with removable adapter hub,
remove hub from rotor.
(6) Remove cotter pin from rotor hub nut and
remove nut (Fig. 60).
Fig. 62 Rotor Hub And Unit Wheel Bearing

Assembly
Fig. 60 Hub Nut Cotter Pin

(7) Remove bolts that secure rotor and hub to
steering knuckle from inboard (back) side of steering
knuckle (Fig. 61).
Fig. 63 Hub Spacer
Fig. 61 Rotor And Hub Attaching Bolts

(8) Remove rotor and hub assembly (Fig. 62).
Replace bearing assembly i f damaged.
(9) Remove hub spacer from steering knuckle (Fig.
63). Note spacer position for installation reference.
INSTALLATION
(1) Apply liberal quantity of Mopar, or Permatex
Fig. 64 Hub Spacer Positioning
anti-seize compound to splines of front drive shaft
(Fig. 64). (3) Insert two rearmost, top and bottom rotor hub
(2) Replace grease seal in steering knuckle i f dam bolts in steering knuckle. Insert bolts through back
aged.
5 - 31 BRAKES
REMOVAL AND INSTALLATION {Continued)

side of knuckle so they extend out front face as
shown.
(4) Position hub spacer on bolts just installed in
knuckle. Be sure flat on spacer Is positioned toward
rear. Use chassis grease to hold spacer in place on
knuckle.
(5) Apply 1-2 drops of Mopar Lock N ' Seal, or Loc-
tite 242 to threads of rotor and hub retaining bolts.
(6) Align rotor hub with ' drive shaft. Then start
shaft Into rotor hub splines.
(7) Align bolt holes In unit bearing flange with
bolts previously installed In knuckle. Then thread
bolts into bearing flange far enough to hold assembly
in place.
(8) Install remaining rotor retaining bolts. Tighten
all bolts securely
(9) Install washer and hub nut. Tighten nut
securely.
(10) Install new cotter pin in hub nut. Tighten nut
as needed to align cotter pin hole in shaft with open
ing in nut. ASSEMBLY ' J9405-16
(11) Install disc brake caliper.
(12) Install wheel and tire assemblies and lower Fig. 65 Brakeshoe Mounting
vehicle. (7) Remove adjuster screw, shoe spring and park
(13) Apply brakes several times to reseat brake- brake strut and spring.
shoes and caliper piston. Do not move vehicle until
firm brake pedal is obtained. CAUTION: The adjuster screw assemblies have dif
ferent threads and must be kept separate. The
FRONT WHEEL BEARING driver side adjuster screw has a right hand thread.
On models with tapered roller front wheel bear And the passenger side adjuster screw has a left
ings, the bearings and races can be serviced when hand thread. Do not interchange them as the brake
necessary. The bearing races do not require special shoes will not adjust properly.
tools for removal. The race can be removed with a
long tapered brass drift. Race installation is per (8) Remove secondary brakeshoe holddown spring,
formed with a bearing race driver set. pin and retainers.
On vehicles with unit style hub bearings the unit (9) Pull adjuster lever and retainer out of second
is a bolted to the knuckle. 2500 and 3500 model vehi ary brakeshoe. Then rotate brakeshoe out arid up
cles with unit style. hub bearing have the disc brake and remove adjuster spring and secondary shoe
rotor pressed onto the unit with the wheel studs. The return spring.
wheel studs must be pressed or driven out in order to (10) Disconnect park brake cable from lever on
separate the rotor from the hub bearing for replace secondary brakeshoe. Then remove brakeshoe.
ment. (11) I f brakeshoes are to be replaced, remove
E-clip (or U-clip) that attaches park brake lever to
BRAKESHOE (11 INCH BRAKE) secondary brakeshoe and remove lever.
REMOVAL INSTALLATION
(1) Raise vehicle. (1) Clean support plate with Mopar brake cleaner.
(2) Remove rear wheels. - Then smooth shoe contact pads with wire brush or
(3) Remove brake drums. emery cloth.
(4) Remove primary (front) brakeshoe return (2) Apply coat of Mopar multi-mileage, or high
spring (Fig. 65) and (Fig. 66). Use brake spring pliers temp bearing grease to each shoe contact pad on sup
to unseat and remove spring from anchor pin. port plate (Fig. 67).
(5) Remove primary shoe holddown spring, pin and (3) Lubricate adjuster levers and anchor pin and
retainers. Use brake spring tool to rotate retainers shoe contact surfaces on support plate with Mopar
and disengage pins. multi-mileage grease, or high temp bearing grease.
(6) Tilt primary brakeshoe outward. Then disen (4) Clean and check operation of adjuster screw
gage shoe spring and remove primary brakeshoe. assemblies. Make sure each screw assembly rotates
BR BRAKES I - 31
REMOVAL AND INSTALLATION fContinued)

CYLINDER SUPPORT ' PARK
FRONT ASSEMBLY RETAINERS J9405-4
Fig. 66 Brakeshoes and Hardware

SUPPORT (7) Position adjuster lever on secondary brakeshoe.
ANCHOR PLATE Then install spring retainer with shoulder on in lever
PIN
and Into shoe.
(8) Position secondary brakeshoe on support plate.
Use new holddown spring, pin and retainer to secure
shoe and adjuster lever.
(9) Attach shoe spring to secondary brakeshoe.
Connect long end of spring i n secondary shoe.
(10) Engage parking brake strut In- secondary
brakeshoe and install oval shaped spring on opposite
end of strut (spring end of strut goes In primary
shoe).
(11) Install primary brakeshoe on support plate.
SHOE CONTACT Use new holddown spring, pin and retainers to
SURFACES J90Q5-14 secure shoe. Be sure parking brake strut is seated i n
both brakeshoes.
Fig. 67 Typical Brakeshoe Contact Pad Locations (12) Install actuator lever and spring. Hook actua
freely. Lubricate screw threads with Mopar spray tor lever under adjuster lever as shown. Large diam
lube. Replace either assembly i f threads are heavily eter end of spring goes on shoe and small end on
rusted, corroded, or damaged. lever.
(5) Attach park brake lever to secondary brake- (13) Install adjuster screw assembly. Be sure star
shoe, use new U-clip to secure lever to shoe. I f U-clip wheel Is positioned adjacent. to adjuster lever and
Is used to secure shoe, pinch clip together with chan that notches i n buttons are properly seated on brake-
nel lock pliers to secure It. I f E-clip is used, be sure shoes.
clip is fully seated In notch.
(6) Attach park brake cable to lever.
5 - 32 BRAKES BR

CAUTION: Be sure the adjuster screws are installed (4) Remove primary (front) brakeshoe return
on the correct side. The driver side adjuster screw has spring from anchor pin with brake spring pliers (Fig.
right hand threads and the passenger side has left 68).
hand threads. Also be sure the short end of the screw (5) Remove primary brakeshoe holddown spring,
is toward the secondary brakeshoe. pin and retainers with holddown spring tool.
(6) Disconnect shoe spring and remove primary
(14) Attach shoe spring to primary brakeshoe. brakeshoe and parking brake lever strut.
(15) Install guide plate on anchor pin. (7) Remove adjuster screw assembly.
(16) Attach adjuster spring to adjuster lever. (8) Remove secondary brakeshoe holddown spring,
(17) Install secondary brakeshoe return spring in pin and retainers. Then remove adjuster lever, spring
shoe. and spring retainer assembly. I t is not necessary to
(18) Attach secondary shoe return spring to adjuster disassemble adjuster lever components unless they
spring. Then install adjuster spring on anchor pin. are worn, or damaged.
(19) Install primary brakeshoe return spring. (9) Disconnect parking brake cable from lever
(20) Verify that adjuster and return springs are attached to secondary brakeshoe. Then remove
properly installed. brakeshoe.
(21) Adjust brakeshoes to drum with brake gauge. (10) I f brakeshoes are to be replaced, remove
(22) Install brake drum and wheel and tire assem E-clip attaching parking brake lever to secondary
blies. brakeshoe and remove lever.
(23) Lower vehicle. (11) Inspect wheel cylinder. I f leakage is evident,
remove and overhaul cylinder. Refer to overhaul pro
BRAKESHOE (13-INCH BRAKE) cedure in this section.
REMOVAL INSTALLATION
(1) Raise vehicle. (1) Clean support plate with Mopar brake cleaner.
(2) Remove rear wheel and tire assemblies. Then smooth shoe contact pads with wire brush or
(3) Remove brake drums. emery cloth.
SECONDARY WHEEL
SHOE . CYLINDER
RETURN ADJUSTER SUPPORT
SPRING LEVER PLATE ANCHOR
SPRING PIN
SECONDARY
BRAKESHOE SHOE
GUIDE
PLATE
SPRING
RETAINER PARK
BRAKE
STRUT PRIMARY
RETAINER AND BRAKESHOE
SPRING SPRING
PRIMARY
SHOE
RETURN
SPRING
ADJUSTER
LEVER
HOLDDOWN
SPRING, PARK
PIN, BRAKE
RETAINERS STRUT
LEVER
SPRING
HOLDDOWN
SPRING, PIN,
ADJUSTER RETAINERS
SCREW SHOE
ASSEMBLY SPRING J9405-19
Fig. 68 Brakeshoes and Hardware (13 inch Brake)

BR BRAKES 5 - 33

(2) Lubricate adjuster levers and anchor pin and
shoe contact surfaces on support plate with Mopar
multi-mileage grease, or high temp bearing grease.
(3) Clean and check operation of both adjuster
screw assemblies. Replace either assembly i f threads
are heavily rusted, corroded, or damaged. Make sure
each screw assembly rotates freely. Then lubricate
adjuster screw threads with Mopar spray lube.
(4) Attach parking brake lever to secondary brake-
shoe. Use new E-clip to secure lever to shoe. I f lever
is secured with U-clip, pinch new clip together with
channel lock pliers to secure it.
(5) Attach parking brake cable to parking brake
lever.
(6) I f adjuster lever was disassembled, reassemble
it as follows:
(a) Clamp adjuster lever in vise (Fig. 69). Fig. 70 Assembling Adjuster Lever, Spring And
Clamp center p o r t i o n of lever i n vise only. Do Retainer
not clamp bottom end of lever i n vise. Lever
(d) Install holddown spring over pin and seat i t
flange that rotates adjuster screw star wheel
in inner retainer. Then install and seat holddown
teeth is at bottom of lever and will be dam
spring outer retainer on pin with holddown spring
aged.
tool.
(b) Position small, hooked spring retainer in
(8) Install adjuster lever spring between brakeshoe
upper end of lever (Fig. 69). Be sure tang on
and lever. Be sure spring is seated on lever tang.
retainer is securely engaged in hole in lever. Lock
(9) Attach shoe spring to secondary brakeshoe.
ing pliers can be used to hold retainer in place
Long end of spring goes in secondary shoe.
after positioning.
(10) Install oval shaped spring on park brake strut
(c) Secure retainer in lever with retainer spring.
and engage spring end of strut in secondary brake-
Hook spring over end of retainer as shown (Fig.
shoe.
70). Needlenose pliers and number 2 Phillips
(11) Install primary brakeshoe on support plate.
screwdriver can be used to attach spring to lever
Use new holddown spring, pin and retainers to
and retainer.
secure shoe. Be sure parking brake strut is seated in
ADJUSTER
both brakeshoes.
ADJUSTER (12) Install adjuster screw assembly. Be sure star
SPRING
LEVER RETAINER wheel is positioned adjacent to adjuster lever and
that notches in adjuster screw are properly seated on
brakeshoes.
CAUTION: Be sure the adjuster screws were not

intermixed and are installed on the correct side.
The driver side adjuster screw has right hand
threads and the passenger side has left hand
J9405-68 threads. Also be sure the short end of the screw is
toward the secondary brakeshoe.
Fig. 69 Positioning Retainer On Adjuster Lever
(7) Install secondary brakeshoe and adjuster lever (13) Attach shoe spring to primary brakeshoe. Use
as follows: brake spring pliers and long screwdriver to seat
(a) Insert secondary shoe holddown pin through spring in shoe.
support plate. (14) Install shoe guide plate on anchor pin.
(b) Position secondary brakeshoe on support (15) Attach adjuster spring to spring retainer at
plate and insert pin through shoe. top of adjuster lever. Then seat spring on anchor pin
(c) Position adjuster lever on brakeshoe and with brake spring pliers.
• insert holddown spring inner retainer into lever (16) Install secondary brakeshoe return spring.
and shoe. Inner retainer has shoulder on i t which Attach short end of spring to brakeshoe. Then hook
seats i n lever and shoe. opposite end on adjuster spring. Use brake spring
BR
R E M O V A L AMP I N S T A L L A T I O N (Continued)
pliers, or a long shank screwdriver to engage return (4) Tighten brake line fitting to 13 N-m (115 in.
spring in adjuster spring. lbs.).
(17) Install primary brakeshoe return spring. (5) Install brakeshoe components.
(18) Check component installation. Be sure (6) • Adjust brakeshoes to drum using brake gauge.
adjuster screw, wheel cylinder links and park brake (7) Install brake drum.
strut are all seated in brakeshoes. (8) Fill and bleed brake system.
(19) Adjust brakeshoes to drum with brake gauge. (9) Install wheel and tire assemblies and lower
(20) Install brake drums. vehicle.
(21) Install wheel and tire assemblies and lower
vehicle. BRAKE SUPPORT PLATE
(22) Install wheel cover or hub cap.
REMOVAL
WHEEL CYLINDER (1) Remove wheel and tire assemblies.
(2) Remove brake drums
REMOVAL (3) Remove axle shaft, refer to Group 3 for proce
(1) Raise vehicle and remove tire and wheel dures.
assembly. (4) Remove brakeshoes and hardware for access to
(2) Remove brake drum. parking brake cable.
(3) Lift adjuster lever away from adjuster screw. (5) Remove parking brake cable from support
Then turn screw star wheel until screw is fully plate.
retracted. (6) Disconnect brake line at wheel cylinder and
(4) Remove brakeshoe return springs, adjuster remove cylinder.
spring and adjuster screw. Move upper ends of brake- (7) Remove bolts attaching support plate to axle
shoes apart to provide removal clearance for wheel and remove support plate.
cylinder links.
(5) Disconnect brake line from wheel cylinder. INSTALLATION
(6) Remove wheel cylinder attaching screws and (1) Apply thin bead of Mopar silicone sealer
remove cylinder from support plate around axle mounting surface of support plate.
(2) Install support plate on axle flange. Tighten
INSTALLATION attaching bolts to 47-68 N-m (35-50 ft. lbs.).
(1) Apply thin coat of Mopar silicone sealer to (3) Apply thin bead of Mopar silicone sealer
wheel cylinder mounting surface of support plate around wheel cylinder mounting surface. Install
(Fig. 71). Sealer prevents road splash from entering wheel cylinder on new support plate.
brake drum past cylinder. (4) Install parking brake cable in support plate.
(5) Install brakeshoes and hardware.
(6) Install axle shaft, refer to Group 3 for proce
dure.
(7) Adjust brakeshoes to drum with brake gauge.
(8) Install brake drums.
(9) Fill and bleed brake system.
(10) Install wheel and tire assemblies and lower
vehicle.
FRONT PARKING BRAKE CABLE
REMOVAL
(1) Remove knee bolster.
(2) Release parking brake pedal completely.
(3) Raise vehicle.
(4) Loosen tensioner nut to create slack in front
cable and extension cable (Fig. 72).
Fig. 71 Wheei Cylinder Mounting Surface
(5) Disengage front cable from extension cable con
(2) Start brake line in cylinder inlet by hand. Do nector. Extension cable also be removed at this time
not tighten fitting at this time. if necessary.
(3) Mount wheel cylinder on support plate and (6) Lower vehicle.
install cylinder attaching screws. Tighten screws to
20 N-m (15 ft. lbs.).
BR BRAKES 5 - 35

PEDAL
ASSEMBLY
CABLE
C O N N ECTORS J9405-169
Fig. 72 Extension-To-Front Cable Attachment

(7) Roll back carpet and loosen cable grommet
(Fig. 73). Then pull cable through floorpan grommet
and remove cable.
J9405-170
Fig. 74 Cable Attachment At Foot Pedal

REAR PARK BRAKE CABLE
REMOVAL
(1) Raise vehicle and remove necessary wheel and
brake drum.
(2) Remove secondary brakeshoe and disconnect
cable from parking lever attached to secondary shoe.
(3) Compress rear cable retainer with hose clamp
or pliers and pull cable out of support plate.
(4) Remove one (or both) cables reaction bracket
on left rear fame rail.
(5) Disengage rear cable from tensioner (Fig. 75).
(6) Compress cable retainer with hose clamp or
pliers and slide cable out of bracket.
Fig. 73 Cable Grommet In Floorpan
INSTALLATION
(8) Disengage front cable from arm on foot pedal
(1) Route new cable to rear brake support plate.
assembly (Fig. 74).
(2) Insert cable through support plate, seat cable
INSTALLATION retainers and attach cable to parking brake lever on
(1) Insert new cable through floorpan grommet secondary brakeshoe.
and up to arm on pedal assembly. (3) Install brakeshoes.
(2) Hook cable T-connector in arm on pedal assem (4) Seat cable in body clips, reaction bracket, and
frame bracket.
bly
(5) Connect cable to tensioner.
(3) Secure floorpan grommet/seal.
(6) Adjust cable tensioner, Refer to procedure i n
(4) Realign floor carpet.
this section.
(6) Engage front cable and extension cable in cable
(8) Lower vehicle.
connectors. Make sure right rear cable is secured in
(9) Verify parking brake operation.
tensioner connector.
(7) Adjust cable tensioner. Refer to procedure in
this section.
5 - 36 BRAKES BR

PEDAL COWL DASH
ASSEMBLY
L.R.
CABLE
EQUALIZER
CABLE
BRACKET
R.R.
CABLE
CABLE
TENSIONER
ITEM TORQUE
J9405-173 A 21-34 N-m (200-300 in. lbs.)
J9405-175
Fig. 75 Cable And Tensioner Attachment Fig. 76 Parking Brake Pedal Mounting
PARKING BRAKE PEDAL DISASSEMBLY AND ASSEMBLY
REMOVAL
MASTER CYLINDER
(1) Release parking brakes.
(2) Raise vehicle. DISASSEMBLY
(3) Loosen cable tensioner nut at equalizer to cre The master cylinder primary piston is serviced as
ate slack in front cable. an assembly. Only the secondary piston can be disas
(4) Lower vehicle. sembled for service. •
(5) Remove knee bolster. (1) Remove reservoir cover and seal (Fig. 77).
(6) Disconnect brakelamp wire from switch on
pedal assembly.
(7) Roll carpet back and loosen front cable grom COVER
met from floorpan.
(8) Disengage cable end connector from arm on
pedal assembly.
(9) Remove bolts/nuts from pedal assembly and DIAPHRAGM
remove assembly (Fig. 76). SEAL
INSTALLATION
(1) Position replacement pedal assembly on dash
RESERVOIR
and cowl.
(2) Install bolts/nuts and tighten to 21-34 N-m
(200-300 in. lbs.).
(3) Connect front cable to arm on pedal assembly.
(4) Connect wires to brakelamp switch. J9405-7
(6) Raise vehicle. Fig. 77 Reservoir Seal And Cover
(7) Adjust parking brake cable tensioner. Refer to (2) Drain reservoir fluid into drain container.
procedure in this section. (3) Clamp cylinder body in vise. Clamp vise jaws
on one of the cylinder mounting ears as shown.
(4) Remove reservoir with a rocking motion. Use a
pry tool to help ease reservoir out of cylinder body
and grommets (Fig. 78). I f reservoir is to be
BR BRAKES 5 - 37

replaced, mote and record reservoir code let CYLINDER
ters. lODY
J9405-10
Fig, 80 Master Cylinder
Fig. 78 Reservoir Removal (10) Remove seal retainer from secondary piston.
Then remove front and rear seals from piston (Fig.
(5) Remove grommets from cylinder body (Fig. 79). 81). Discard seals, spring, and retainer after these
Discard grommets as they are not reusable. parts are not reusable.
SPRING
-9
PISTON J9405-11
Fig. 79 Reservoir Grommet

Fig. 81 Secondary Piston Components
(6) Remove master cylinder piston retaining snap
ring with small pointed tool and flat blade screw
Clean the cylinder body and reservoir with Mopar
driver.
brake cleaner only. Do not use any other type of
(7) Remove primary piston and spring assembly
cleaning solvent. Dry the cylinder parts with com
(Fig. 80). Discard assembly, primary piston is
pressed air. The reservoir can be air dried or wiped
only serviced as complete assembly.
dry with lint-free shop towels.
(8) Remove secondary piston by apply air pressure
Inspect the cylinder bore. A light discoloration of
through rear outlet port to ease piston out of bore.
the bore surface is normal and acceptable. However,
(9) Remove secondary piston spring by tilting the
replace the cylinder body i f the bore is scored, pitted,
cylinder body downward so the spring slides out of
or corroded.
bore.
5 - 38 BRAKES BR
DISASSEMBLY AND ASSEMBLY {Continued)

Inspect the cylinder cover and diaphragm seal.
Eeplace the seal i f torn, or distorted. Replace the
cover If warped, cracked, or the snap fasteners are
damaged.
Inspect the reservoir. A slight discoloration of the
reservoir surface is normal. Replace the reservoir If
distorted, cracked, or otherwise damaged.
Inspect the take up valve in the cylinder body. The
valve should move freely and not be stuck or seized.
The valve Is not serviceable. I t will be necessary to
replace the cylinder body i f the valve is faulty.
Inspect condition of the secondary piston. Replace
the piston i f it is scored, corroded, or doubt exists
about its condition.
ASSEMBLY
(1) Coat cylinder body bore, piston components and
reservoir grommets with fresh, clean brake fluid.
(2) Mount cylinder body i n vise. Clamp one cylin
RESERVOIR
der mounting ear in vise jaws.
(3) Assemble secondary piston components. Be J9405-12
careful when installing seals. Avoid distorting them
Fig. 82 Assembling Reservoir
during installation.
DISC BRAKE CALIPER
CAUTION: Do not use any kind of metal tool to
ease piston seal installation in the cylinder bore. DISASSEMBLY
Metal tools will cut the seals and scratch the bore. (1) Drain brake fluid from caliper.
If a tool is needed, use a small flexible item made (2) Remove brakeshoes from caliper.
from nylon, rubber or plastic only. (3) Pad interior of caliper with one-inch thickness
of shop towels to cushion and protect caliper piston
(4) Install secondary piston assembly (spring end during removal (Fig. 83).
first), in cylinder bore. Bo not force piston into bore. (4) Remove caliper piston with several short
Work i t into place w i t h a twisting/turning motion. bursts of low pressure compressed air. Direct air
(5) Install primary piston i n cylinder bore (spring through fluid inlet port to ease piston out of bore
end first). Do not force piston i n t o bore. Work i t (Fig. 83).
into place w i t h a t w i s t i n g / t u r n i n g motion,
(6) Insert piston retaining snap ring in cylinder CAUTION: Do not blow the piston out of the bore
body. Then push pistons inward with wood dowel and with sustained high pressure. This practice will
seat snap ring. result in a chipped, or cracked piston. In addition,
NEVER attempt to catch the piston as it exits the
CAUTION; Be very sure the piston retaining snap bore. This will result in personal injury.
ring is fully seated. Recheck snap ring installation
before proceeding.
(7) Install new grommets on cylinder body.

(8) Remove cylinder body from vise.
(9) Position reservoir on clean work surface with
fluid inlet necks facing upward. Padding work surface
with clean shop towels will keep reservoir in place dur
ing installation. It will also keep dirt out as well.
(10) Install cylinder body on reservoir by rocking
the cylinder onto the reservoir necks (Fig. 82).
(11) Verify that reservoir is properly seated and
that grommets have not slipped out of place.
(12) Bleed master cylinder on bench before install
ing i t in vehicle.
Fig. 83 Caliper Piston Removal
BR BiAlES 5-3S
DISASSEMBLY AND ASSEMBLY ( C o n t i n u e d )

(5) Remove piston dust boot with a suitable pry 86). Remove these components only i f cut, worn, or
tool (Fig. 84). Do not scratch piston bore while damaged.
removing boot. Discard dust boot as i t Is not reus (8) Remove caliper bleed screw.
able.
ASSEMBLY
PRY NOTE; Be sure caliper assembly area of workbench

TOOL is clean and dry. This is important as dust, dirt, for
eign material, oil, or solvents can damage seals,
harm piston surfaces and contaminate fluid.
(1) Clean the caliper and piston with Mopar brake

cleaner, clean brake fluid, or denatured alcohol. Do
not use any other cleaning agents.
(2) Inspect condition of the caliper piston bore. The
piston must be free of corrosion, rust, pitting, or scor-
ing. replace the piston i f i t exhibits any of these con
DUST ditions.
BOOT (3) A fiber brush can be used to clean the bore i f
J9405-39 necessary. The bore should be free of corrosion, pit
ting, or scoring. Discoloration of the bore is a normal
Fig. 84 Dust Boot Removal condition and not cause for replacement. The bore
can be lightly polished by hand but only with crocus
(6) Remove piston seal from caliper and discard
cloth.
seal It is not reusable (Fig. 85) and (Fig. 86).
(7) Remove mounting bolts from calipers and
inspect seals, boots, and bushings (Fig. 85) and (Fig.
J9405-36
Fig. 85 Caliper Components (75mm Caliper)

5 - 40 BRAKES - BR
DISASSEMBLY AND ASSEMBLY {Continued)
MOUNTING
BOLTS
CALIPER
PISTON
SEAL .
INBOARD
BRAKESHOE
OUTBOARD
BRAKESHOE
CALIPER
PISTON
BLEED DUST
SCREW SOOT
J9405-37
Fig. 86 Caliper Components (80/86mm Caliper)

CAUTION: Never hone the caliper piston bore, or
use any kind of abrasive material on the piston sur
face. Honing will result in an oversize bore and
abrasives will damage the piston coating. Either of
these practices will result in piston bind and even
tual seizure.
(4) Inspect condition of the threads in the inlet

and bleed screw ports. Replace the caliper i f thread
damage is evident. Do not attempt to salvage the
threads.
(5) Check the bushings i n the caliper mounting BOOT UP
• CALIPER IN PISTON"
bolt bores. Replace the bushings i f worn, cut, or torn. PISTON GROOVE "
(6) Lubricate caliper piston, piston seal and piston
bore with liberal quantity of clean, fresh brake fluid.
(7) Lightly lubricate lip of new boot with Dow or
GE silicone grease. Install boot on piston and work
boot lip into the groove at the top of piston (Fig. 87).
(8) Stretch boot rearward to straighten boot folds,
then move boot forward until folds snap into place
(Fig. 87).
(9) Install new piston seal into caliper bore.Be
sure square cut seal is fully seated and is not
twisted.
(10) Install piston into caliper bore. Once piston is
started into the piston seal, press piston 3/4 of way
down into the caliper bore by hand or with hammer ^J9405-40
handle.
(11) Seat dust boot in caliper with installer (Fig. Fig. 87 installing Dust Boot
88):
' • 1/2 ton 75mm caliper: Installer 6753 (12.) Press piston to the bottom of the caliper bore.
• 3/4 ton 80 mm caliper: Installer 6754
• 1 ton 86mm caliper: Installer 6755
BR BRAKES 5 - 41

spring and expander) and flat side is against
piston.
(3) Install spring and expander followed by
remaining piston cup and piston.
(4) Install boots on each end of cylinder and insert
push rods in boots.
(5) Install cylinder bleed screw.
REAR DRUM BRAKE

CLEANING
Clean the individual brake components, including
the support plate and wheel cylinder exterior, with a
water dampened cloth or with Mopar brake cleaner.
Do not use any other cleaning agents. Remove light
rust and scale from the brakeshoe contact pads on
the support plate with fine sandpaper.
INSPECTION
As a general rule, riveted brakeshoes should be
Fig. 88 Seating Dust Boot
replaced when worn to within 0.78 mm (1/32 in.) of
(13) Lubricate caliper mounting bolts, collars, the rivet heads. Bonded lining should be replaced
bushings and bores with Dow 111, or GE 661 silicone when worn to a thickness of 1.6 mm (1/16 in.).
grease. Examine the lining contact pattern to determine i f
(14) Install bushings, seals, boots and mounting the shoes are bent or the drum is tapered. The lining
bolts In caliper (Figs. 23 and 24). should exhibit contact across its entire width. Shoes
(15) Install caliper bleed screw. exhibiting contact only on one side should be
replaced and the drum checked for runout or taper.
WHEEL CYL11DER Inspect the adjuster screw assembly. Replace the
assembly If the star wheel threads are damaged, or
DISASSEMBLY the components are severely rusted or corroded.
(1) Remove push rods and boots (Fig. 89). Discard the brake springs and retainer components
(2) Press pistons, cups and spring and expander if worn distorted, or collapsed. Also replace the
out of cylinder bore. springs i f a brake drag condition had occurred. Over
(3) Remove bleed screw. heating will distort and weaken the springs.
Inspect the brakeshoe contact pads on the support
plate, replace the support plate If any of the pads are
worn or rusted through. Also replace the plate i f it.is
bent or distorted (Fig. 90).
CALIPER
CLEANING
Clean the caliper components with clean brake
fluid or Mopar brake cleaning solvent only. Do not
use gasoline, kerosene, thinner, or similar solvents.
These products may leave a residue that could dam
Fig. 89 Wheel Cylinder Components age the piston and seal.
Wipe the caliper and piston dry with lint free tow
ASSEMBLY
els or use low pressure compressed air.
(1) Lubricate wheel cylinder bore, pistons, piston
cups and spring and expander with clean brake fluid. INSPECTION
(2) Install first piston in cylinder bore. Then The piston Is made from a phenolic resin (plastic
Install first cup i n bore and against piston. Be sure material) and should be smooth and clean.
l i p of piston cup is facing i n w a r d (toward
CLEAHiNG AND I N S P E C T I O N fContinued)
WHEEL C Y L i l i E R
CLEANING
Clean the cylinder and pistons with clean brake
fluid or brake cleaner only. Do not use any other
cleaning agents.
Dry the cylinder and pistons with compressed air.
Do not use rags or shop towels to dry the cylinder
components. Lint from cloth material will adhere to
the cylinder bores and pistons.
INSPECTION
Inspect the cylinder bore. Light discoloration and
dark stains In the bore are normal and will not
impair cylinder operation.
;
The cylinder bore can be lightly polished but only
' Fig. 90 Shoe Contact Surfaces with crocus cloth. Replace the cylinder i f the bore is
Replace the piston i f cracked or scored. Do not scored, pitted or heavily corroded. Honing the bore to
attempt to restore a scored piston surface by sanding restore the surface is not recommended.
or polishing. The piston must be replaced i f damaged. Inspect the cylinder pistons. The piston surfaces
should be smooth and free of scratches, scoring and
NOTE: If the caliper piston must be replaced, corrosion. Replace the pistons i f worn, scored, or cor
install the same type of piston in the caliper. Newer roded. Do attempt to restore the surface by sanding
interchange phenolic resin and steel caliper pis or polishing.
tons. The pistons, seals, seal grooves, caliper bore Discard the old piston cups and the spring and
and piston tolerances are different for resin and expander. These parts are not reusable. The original
steel pistons. Do not intermix these components at dust boots may be reused but only If they are in good
any time. condition.
The bore can be lightly polished with a brake hone

to remove very minor surface imperfections (Fig. 91). ADJUSTMENTS
The caliper should be replaced i f the bore is severely
corroded, rusted, scored, or i f polishing would STOP LAMP SWITCH
increase bore diameter more than 0.025 mm (0.001 (1) Push and hold brake pedal down
inch). (2) Pull switch plunger all the way out to fully
extended position.
SPECIAL HONE CALIPER (3) Push switch plunger Inward 4 detent positions
(or clicks). This is required preset position. Plunger
will extend approximately 14 mm (0.55 in.) out of
housing at this setting.
(4) Release brake pedal. Then lightly pull pedal
fully rearward. Pedal will adjust switch plunger to
correct position as pedal is moved to rear.
CAUTION: Do not use excessive force to move the

pedal rearward for switch adjustment. Excessive
force will damage t h e switch.
REAR DRUM BRAKE

The rear drum brakes are equipped with a self-ad
Fig. 91 Lightiy Polishing Piston Bore With Tool justing mechanism. Under normal circumstances, the
only time adjustment is required is when the shoes
are replaced, removed for access to other parts, or
when one or both drums are replaced.
Adjustment can be made with a standard brake
gauge or with adjusting tool. Adjustment is per-
BR HUES 5 • 43
formed with the complete brake assembly Installed (8) Install brake drums and wheels and lower
on the backing plate. vehicle.
(9) Drive vehicle and make one forward stop fol
ADJUSTMENT WITH BRAKE GAUGE lowed by one reverse stop. Repeat procedure 8-10
(1) Be sure parking brakes are fully released. times to operate automatic adjusters and equalize
(2) Raise rear of vehicle and remove wheels and adjustment.
brake drums.
(3) Verify that left and right automatic adjuster NOTE: Bring vehicle to complete standstill at each
levers and cables are properly connected. stop. Incomplete, roiling stops will not activate
(4) Insert brake gauge In drum. Expand gauge automatic adjusters.
until gauge inner legs contact drum braking surface.
Then lock gauge in position (Fig. 92).
ADJUSTMENT WITH ADJUSTING TOOL
(1) Be sure parking brake lever is fully released.
(2) Raise vehicle so rear wheels can be rotated
freely.
(3) Remove plug from each access hole In brake
support plates.
(4) Loosen parking brake cable adjustment nut
until there is slack in front cable.
(5) Insert adjusting tool through support plate
access hole and engage tool In teeth of adjusting
screw star wheel (Fig. 94).
Fig. 92 Adjusting Gauge On Drum

(5) Reverse gauge and install it on brakeshoes.
Position gauge -legs at shoe centers as shown (Fig.
93). i f gauge does not fit (too loose/too tight), adjust
shoes.
BRAKE SHOES
Fig. 94 Brake Adjustment

(6) Rotate adjuster screw star wheel (move tool
handle upward) until slight drag can be felt when
wheel is rotated.
(7) Push and hold adjuster lever away from star
wheel with thin screwdriver.
(8) Back off adjuster screw star wheel until brake
drag is eliminated.
(9) Repeat adjustment at opposite wheel. Be sure
adjustment Is equal at both wheels.
Fig, 93 Adjusting Gauge On Brakeshoes (10) Install support plate access hole plugs.
(6) Pull shoe adjuster screw star wheel away from (11) Adjust parking brake cable and lower vehicle.
adjuster lever. (12) Install brake drums and wheels and lower
(7) Turn adjuster screw star wheel (by hand) to vehicle.
expand or retract brakeshoes. Continue adjustment (13) Drive vehicle and make one forward stop fol
until gauge outside legs are light drag-fit on shoes. lowed by one reverse stop. Repeat procedure 8-10
5 - 44 BRAKES BR
times to operate automatic adjusters and equalize
CABLE
adjustment. CONNECTOR
THREADED
NOTE: Bring vehicle to complete standstill at each ROD
(TO EQUALIZER)
stop. Incomplete, rolling stops will not activate
automatic adjusters. TENSIONER
ROD
PARKING BRAKE CABLE TENSIONER ADJUSTMENT
NOTE: Tensioner adjustment is only necessary

when the tensioner, or a cable has been replaced or
disconnected for service. When adjustment is nec
essary, perform adjustment only as described in the
following procedure. This is necessary to avoid PLACE
faulty parking brake operation. MARK
HERE
(1) Raise vehicle.

(2) Back off cable tensioner adjusting nut to create
slack in cables. T E N S I O N E R BRACKET
(3) Remove rear wheel and tire assemblies. Then
remove brake drums. J9405-176
(4) Check rear brakeshoe adjustment with stan
dard brake gauge. Fig. 95 Adjustment Mark On Cable Tensioner Rod
(5) Replace worn brakeshoes i f necessary.
SPECIFICATIONS
(6) Verify parking brake cables operate freely.
Replace faulty cables if necessary.
BRAKE FLUID
(7) Install drums and verify that drums rotate
The brake fluid used in this vehicle must conform
freely without drag.
to DOT 3 specifications and SAE J1703 standards.
(8) Install wheel/tire assemblies.
No other type of brake fluid is recommended or
(9) Lower vehicle enough for access to parking
approved for usage in the vehicle brake system. Use
brake foot pedal.
only Mopar brake fluid or an equivalent from a
(10) Fully apply parking brakes and leave brakes
tightly sealed container.
applied until adjustment is complete.
(11) Raise vehicle again. CAUTION: Never use reclaimed brake fluid or fluid
(12) Mark tensioner rod 6.5 mm (1/4 in.) from edge from an container which has been left open. An
of tensioner bracket (Fig. 95). open container will absorb moisture from the air
(13) Tighten adjusting nut at equalizer until mark and contaminate the fluid.
on tensioner rod moves into alignment with tensioner
bracket (Fig. 95).
CAUTION: Never use any type of a petroleum-
CAUTION: Do not loosen, or tighten the tensioner based fluid in the brake hydraulic system. Use of
adjusting nut for any reason after completing such type fluids will result in seal damage of the
adjustment. vehicle brake hydraulic system causing a failure of
the vehicle brake system.
(14) Release parking brake and verify rear wheels
rotate freely without drag. Then lower vehicle.
BR — — — — — — _ _ — — — ^ — BRAKES 5
S P E C I F I C A T I O N S (Continued)
BASE BRAKE SPECIAL TOOLS
Disc Brake Caliper . BASE BRAKES

Type. Sliding
Caliper Piston Diameter
1/2 Ton Model . 75 mm (2.95 in.) ( X
3/4 Ton Model . . . . . . . . . . . . . . . .80 mm (3.14 In.) \ \
1 Ton Model . . . 86 mm (3.38 in.) \
Disc Brake Rotor \//j/j)
1/2 Ton Model Size . . .2.94x32 mm (11.57x1.26 in.) (£y /]
3/4 Ton Model Size . . . .317.5x38 mm (12.5x1.5 in.)
1 Ton Model Size 317.5x 8 mm (12.5x1.5 in.)
Max. Runout 0.127 mm (0.005 in.)
Max^Thickness Variation. . . .0.025 mm (0.001 in.) / # j s f ^ B o Q f ^
Drum Brake
1/2 Ton Model Size . . . .279x51 mm (11x2 in.)
3/4 Ton Model Size 330x63.5 mm (13x2.5 in.) /""V
1 Ton Model Size 330x89 mm (13x3.5 in.) \ \
Max. Runout 0.20 mm (0.008 in.) \
Max. Thickness Variation 0.076 mm (0.003 in.)
Wheel Cylinder Bore Size Yg J IJ)
1/2 Ton Model. . . . . . . . . . . . . .23.8 mm (0.937 in.)
3/4 Ton Model 23.8 mm (0.937 in.)
1 Ton Model . .27 mm (1.06 in.)
Master Cylinder Bore Size
1/2 Ton Model ...... 28.6 mm (1.125 in.) Installer, Brake Caliper Dust Boot 6754
3/4 Ton Model. . . . . . . . . . . . . . .31.8 mm (1.25 In.)
1 Ton Model .31.8 mm (1.25 in.) / ~ v
Brake Booster V \>
1/2 Ton Model Dual Diaphragm \ \
3/4 Ton Model . . . . .Dual Diaphragm High Output \
1 Ton M o d e l . . . . . . .Dual Diaphragm High Output / / / ) ]))
TORQUE CHART
DESCRIPTION TORQUE
Booster
Mounting Nuts . . . . . .23-34 N-m (200-300 i n . lbs.) Installer, Brake Caliper Dust Boot 6755
Diesel Vacuum Pump
Mounting Bolts 77 N-m (57 ft. lbs.)
Master Cylinder
Mounting Nuts . . . . . .23-34 N-m (200-300 in. lbs.)
Brake Lines . .16-23 N-m (140-200 in. lbs.)
Combination Valve
Mounting Nuts . . 23-34 N-m (200-300 in. lbs.)
Brake Lines. . . . . . . . .16-23 N-m (140-200 in. lbs.)
Caliper
Wheel Cylinder
Brake Line . 13 N-m (115 in. lbs.)
Support Plate
Mounting Bolts 47-68 N-m (35-50 ft. lbs.)
Park Brake Pedal Assembly
Mounting Bolts/Nuts . .21-34 N-m (200-300 in. lbs.)
5 - 46 BRAKES BR
REAR W H E E L A N T I L O C K fRWAL) B R A K E S
INDEX
page page
DESCRIPTION AND OPERATION RWAL DIAGNOSTIC PROCEDURE—TEST 2 . . . 57

REAR W H E E L ANTILOCK . . . . . . ....... 46 RWAL DIAGNOSTIC TROUBLE CODES ... . 53
R W A L C O M P O N E N T A B B R E V I A T I O N LIST . . . . . 46 ' RWAL GENERAL DIAGNOSTIC INFORMATION . 51
RWAL C O M P O N E N T LOCATION 47 RWAL PERFORMANCE CHARACTERISTICS . . . 51
RWAL S Y S T E M C O M P O N E N T S 48 RWAL SYSTEM SELF DIAGNOSTICS .... 53
RWAL S Y S T E M OPERATION 51 RWAL VERIFICATION TEST 66
D I A G N O S I S AND T E S T I N G SERVICE PROCEDURES
ABS SERVICE PRECAUTIONS 54 RWAL BRAKE BLEEDING 66
RWAL DIAGNOSIS P R O C E D U R E S — T E S T 3 . . . 60 REMOVAL AND INSTALLATION
RWAL DIAGNOSIS . . . . . . . . 54 EXCITER RING . . . . . . . . . . . . . . . . . . . . . . . . . 69
RWAL DIAGNOSTIC P R O C E D U R E S — T E S T 1 . . 55 REAR W H E E L S P E E D SENSOR . . 69
RWAL DIAGNOSTIC P R O C E D U R E S — T E S T 4 . . 61 RWAL CONTROLLER 68
RWAL DIAGNOSTIC P R O C E D U R E S — T E S T 5 . . 62 R W A L V A L V E / C O M B I N A T I O N VALVE 67
RWAL DIAGNOSTIC P R O C E D U R E S — T E S T 6 . . 62 SPECIFICATIONS
R W A L D I A G N O S T I C P R O C E D U R E S — T E S T 7 .•. 64 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 69
REAR WHEEL ANTILOCK

A Rear Wheel Antilock (RWAL) brake system is
standard equipment on all Dodge trucks and full size
vans (Fig. 1). This system utilizes a standard vacuum
operated power brake booster and a standard master
cylinder. When the brakes are applied, hydraulic
fluid is routed from the master cylinder's secondary
circuit to the RWAL valve (Hydraulic Control Unit -
HCU). From there hydraulic fluid is routed to the
rear brake wheel cylinders. During a normal stop
hydraulic brake fluid flows to the rear wheel cylin
ders unrestricted to allow the vehicle to stop. During
an ABS stop, the HCU modulates the hydraulic
brake pressure to the rear wheels.
The RWAL brake system is designed to prevent
rear wheel lock-up under heavy braking conditions
on virtually all types of road surfaces. Antilock brak
ing is desirable because a vehicle which is stopped
without locking the wheels will retain directional sta
bility and some steering capability. This allows the
driver to retain greater control of the vehicle during Fig, 1 Rear Wheei Antilock (RWAL)
braking. of the RWAL brake system, refer to the appropriate
The RWAL brake system operates by using a Con section in this group of the Service Manual for the
troller Antilock Brake (CAB) to constantly monitor specific details.
rear wheel speed through the rear wheel speed sen
sor. I f a wheel is about to lock-up, the CAB signals RWAL COMPONENT ABBREVIATION LIST
the rear hydraulic control unit to rapidly turn on and In this section of the service manual, the following
off. This valve action will hold, release, and reapply abbreviations are used for the components of the
hydraulic brake fluid pressure to the rear brakes. Kelsey Hayes RWAL brake system.
This section of the Service Manual covers the • CAB - Controller Antilock Brake
description, operation, diagnosis, and on car service • DLC - Data Link Connector
BR BRAKES 5 - 47
D E S C R I P T I O N AND O P E R A T I O N ( C o n t i n u e d }
• DTC - Diagnostic Trouble Code
• HCU - Hydraulic Control Unit
• ABS - Antilock Brake System
• WSS - Wheel Speed Sensor
RWAL COMPONENT LOCATION
COMPONENT LOCATION FUNCTION

CONTROLLER ANTILOCK BRAKE Center of instrument panel. Gathers information from various
inputs to control the rear brake
system during an ABS stop. Also, it
monitors the ABS system for proper
operation
DATA L I N K C O N N E C T O R Located to the right of the steering Provides a means to activate the
column, below the knee blocker. CAB's diagnostic trouble code read
out.
HYDRAULIC CONTROL UNIT Located under the master cylinder Provides modulation of the hydraulic
and is mounted on a bracket with portion of the rear brakes during an
the combination valve. ABS stop.
REAR W H E E L SPEED SENSOR Mounted at the top of the rear axle Sends an AC voltage sinewave to
housing. the CAB whose frequency is
proportional to vehicle speed.
EXCITER RING Attached to the ring gear inside the Provides a means to pull the
differential housing. magnetic field across the wheel
speed sensor's windings.
RED BRAKE WARNING LAMP Located in the instrument cluster. Provides the driver with a indicator
of park brake engagement,
hydraulic brake malfunction, or ABS
malfunction. Also, is used to identify
any diagnostic trouble codes.
AMBER ABS WARNING LAMP Located next to the red brake Provides the driver with an indicator
warning lamp in the instrument of an ABS malfunction and is used
cluster. to identify any diagnostic trouble
codes.
BRAKE WARNING LAMP DIODE Located in the instrument panel Provides a means to isolate the
harness near the parking brake park brake switch circuit from the
switch. CAB for proper red brake warning
lamp operation.
I S O L A T I O N A N D D U M P VALVE Located internally to the CAB. Provides a fail-safe device for
FUSE unwanted control of the isolation
and dump solenoid/valves
ISOLATION A N D D U M P Located internally to the HCU. Provides modulation of the hydraulic
SOLENOID/VALVES portion of the rear brakes during an
ABS stop.
I - 4S BRAKES BR
RWAL SYSTEM COMPONENTS in any one of its monitored circuits, i t will illuminate
the red brake warning and ABS warning lamps. I t
CONTROLLER ANTILOCK BRAKES will then generate a Diagnostic Trouble Code (DTC)
The Controller Antilock Brakes (CAB) is a micro and store i t i n memory. I n general, the diagnostic
processor which monitors and controls the ABS brake trouble code will remain i n memory when the igni
system operation (Fig. 2). I t has a 14 terminal con tion key has been turned OFF. The exception to this
nector to deliver power and ground to the CAB and is codes 9 and 11 which are erased any time the key
connect all inputs and outputs associated with the has been turned OFF. Also, code 11 will be removed
ABS system. The CAB primary functions are: from memory when the ignition is in the RUN or
® Detect wheel locking tendencies. ACC. positions i f the malfunction that caused the
• Control the application of brake fluid pressure to code has been eliminated. For both codes 9 and 11, i f
the rear brakes during antilock braking. the malfunction remains, the DTC will be reset on
• Monitor the RWAL brake system for proper oper the next ignition key cycle to ON.
ation.
• Perform self-check diagnostics. Cab Inputs
The CAB monitors the following inputs to deter
RWAL
C O N T R O L L E R ANTILOCK
mine when a wheel locking tendency may exists:
BRAKES • Rear Wheel Speed Sensor
© Brake Lamp Switch
® Brake Warning Lamp Switch
• Reset Switch
• 4WD Switch (If equipped)
Cab Outputs
The CAB controls the following outputs for antilock
braking and brake warning information:
• RWAL Valve
® ABS Warning Lamp
• Brake Warning Lamp
Power Supply And Ground

Ignition voltage is provided to the CAB through
pin 3 and is protected by a 20 amp fuse. Ignition
voltage is supplied when the ignition switch is in the
RUN or ACC. positions. The CAB requires ignition
voltage to be able to operate the function of antilock
8031e890
brakes. Battery voltage is provided to the CAB
through pin 9 and is protected by a 20 amp fuse.
Fig. 2 RWAL CAB This circuit supplies power to the memory cells so
The CAB continuously monitors the speed of the that the CAB can retain diagnostic information.
differential ring gear by monitoring signals generated Except for trouble codes 9 and 11, the CAB stores
by the rear wheel speed sensor. The CAB determines DTCs in the battery fed volatile memory. Volatile
a wheel locking tendency when i t recognizes the ring memories only retain information as long as power is
gear decelerating too rapidly. supplied to the memory. I f a DTC is stored in the
When a wheel-locking tendency is detected, - the battery fed volatile memory, the DTC can be cleared
CAB energizes the isolation solenoid in the RWAL from the memory by disconnecting the battery supply
valve. When the isolation solenoid is energized, to the CAB. Trouble codes 9 and 11 are also in a vol
hydraulic pressure cannot be increased to the rear atile memory but their memories are fed with igni
wheel cylinders. I f the rear wheel speed sensor still tion voltage. A ground is provide to the CAB through
indicate that the ring gear is decelerating too rapidly, pin 12 of the 14-way connector. I t is required by the
the CAB then energizes the dump solenoid to reduce CAB to be able to operate any of its circuits.
pressure at the rear wheel cylinders. The CAB con
tinues this action until the wheel-locking tendency no REAR WHEEL SPEED SENSOR AND EXCITER
longer exists. RING
When a fault is detected, the CAB will generate The rear Wheel Speed Sensor (WSS) is mounted in
and store diagnostic trouble codes. Only one code can the rear differential housing (Fig. 3). The WSS con
be stored at any one time. I f the CAB senses a fault sists of a magnet surrounded by windings from a sin-
BR BRAKES 5 - 49

gle strand of wire. The sensor sends a small AC 5). Every time a tooth of the exciter ring passes the
signal to the CAB. This signal is generated by mag tip of the WSS, .an AC signal is generated. Each AC
netic induction. The magnetic induction is created signal (positive to negative signal or sinewave) is
when a toothed sensor ring (exciter ring or tone interpreted by the CAB. I t then compares the fre
wheel) passes the stationary magnetic WSS. quency of the sinewave to a time value to calculate
vehicle speed. The CAB continues to monitor the fre
SENSOR quency to determine a deceleration rate that would
WIRE
CONNECTOR REAR BRAKE SENSOR indicate a possible wheel-locking tendency.
SPEED COVER
SENSOR / SENSOR
ASSEMBLY ' /WIRE MAGNETIC
CORE
SPEED
SENSOR
V
COIL*
CAB
AIR GAP
SENSOR \L
WIRE
AXLE
HOUSING J9305-37
Fig. 3 Rear Wheel Speed Sensor Location

The exciter ring is press fitted onto the differential 8020cd59
carrier next to the final drive ring gear (Fig. 4). For
Fig. 5 Operation of the Wheel Speed Sensor
service replacement of the exciter ring, refer to sec
tion 3 of this Service Manual. The signal strength of any magnetic induction sen
sor is directly affected by:
• Magnetic field strength; the stronger the mag
netic field, the stronger the signal
• Number of windings in the sensor; more wind
ings provide a stronger signal
• Exciter ring speed; the faster the exciter ring
rotates, the stronger the signal will be
• Distance between the exciter ring teeth and
WSS; the closer the WSS is to the exciter ring, the
stronger the signal will be
The rear WSS is not adjustable. A clearance speci
fication has been established for manufacturing toler
ances. I f the clearance is not within these
specifications, then either the WSS or other compo
nents may be damaged. The clearance between the
WSS and the exciter ring is 0.005 - 0.050 in.
Fig. 4 Exciter Ring Location The assembly plant performs a "Rolls Test" on
every vehicle that leaves the assembly plant. One of
When the ring gear is rotated, the exciter ring the test performed is a test of the WSS. To properly
passes the tip of the WSS. As the exciter ring passes test the sensor, the assembly plant connects test
the tip of the WSS, the magnetic lines of force of the equipment to the Data Link Connector (DLC). This
sensor are cut, causing the magnetic field to be connector is located to the left of the steering column
moved across the sensor's windings. This, in turn and attached to the lower portion of the instrument
causes current to flow through the WSS circuit (Fig. panel (Fig. 6). The rolls test terminal is spliced to the
5 - 50 BRAKES
D E S C R I P T I O N AND OPERATION fContinued)

WSS circuit. The vehicle is then driven on a set of rate or the desired slip rate programmed into the
rollers and the WSS output is monitored for proper CAB. The system will switch to normal braking once
operation. wheel locking tendencies are no longer present.
A predetermined maximum number of consecutive
dump cycles can be performed during any one
antilock stop, i f excessive dump cycles occur, a DTC
will be set and stored in the CAB memory, i f during
CONNECTOR
an antilock stop, the driver releases the brake pedal,
the reset switch contacts will open. This signal to the
CAB is an indication that pressure has equalized
across the RWAL valve. The CAB will then reset the
dump cycle counter in . anticipation of the next
antilock stop. Additionally, any fluid stored in the
accumulator will force its way past the dump valve,
back into the hydraulic circuit and return to the mas
ter cylinder.
A fuse internal to the CAB, provides a fail-safe
device which prevents unwanted control over the iso
lation and dump solenoids. The fuse is in series with
the isolation and dump solenoids output circuits. I f
the internal fuse is open, the CAB cannot provide
voltage to energize either solenoid and antilock stops
are prevented. I f the fuse is open, the braking system
will operate normally but without antilock control
over rear brake pressure.
Fig. 6 Data Link Connector
WARNING LAMPS
STOP LAMP SWITCH In the RWAL brake system, as in other brake sys
The primary function of the switch is to turn on tems, the brake warning lamp (red) is used to alert
the stop lamps during braking. The switch is also the driver of a hydraulic fault or that the parking
used to send signals to components that must know brake is applied. However, in the RWAL system, the
when the brakes are applied, such as the Powertrain brake warning lamp is also used to alert the driver
Control Module (PCM), which uses the signal to can that there is a problem with the RWAL system.
cel speed control. The CAB uses the brake switch sig There is also an ABS warning lamp (amber). The
nal to monitor brake pedal application. When the ABS warning lamp is only used to alert the driver of
switch contacts open (brakes applied), the CAB RWAL malfunctions and to identify DTCs stored in
receives the brake applied signal. The CAB then the CABs memory.
monitors the ABS system to anticipate the need for
an ABS stop. Brake Warning Lamp
The brake warning lamp illuminates when ignition
RIVAL VALVE voltage is supplied to the bulb and a ground is pro
If the CAB senses that rear wheel speed decelera vided for the bulb. The bulb has ignition voltage sup
tion is excessive, i t will energize a isolation solenoid plied to i t any time the ignition switch is in the RUN
by providing battery voltage to the solenoid. This or START positions. A ground for the bulb is provided
prevents a further increase of driver induced brake by the:
pressure to the rear wheels, i f this initial action is ® Ignition switch during the START mode
not enough to prevent rear wheel lock-up, the CAB © Parking brake switch when the park brake is
will momentarily energize a dump solenoid (the CAB applied
energizes the dump solenoid by providing battery • Brake warning lamp switch when a hydraulic
voltage to the solenoid). This opens the dump valve fault has occurred
to vent a small amount of isolated rear brake pres • CAB during diagnostics and when a RWAL fault
sure to an accumulator. The action of fluid moving to has occurred
the accumulator reduces the isolated brake pressure
at the wheel cylinders. The dump (pressure venting) ABS Warning Lamp
cycle is limited to very short time periods (millisec The ABS warning lamp illuminates when ignition
onds). The CAB will pulse the dump valve until rear voltage is supplied to the bulb and a ground is pro
wheel deceleration matches the vehicle deceleration vided for the bulb. The bulb has ignition voltage sup-
BRAKES 5 - 51
D E S C R I P T I O N AND OPERATION (Continued)
plied to it anytime the ignition switch is in the RUN noid. This prevents a further increase of driver
or START positions. A ground for the bulb is provided induced brake pressure to the rear wheels. I f this ini
by the CAB only. A circuit in the CAB monitors the tial action is not enough to prevent rear wheel lock
brake warning lamp switch and the ignition switch up, the CAB will momentarily energize a dump
bulb check circuit (grounds the brake warning lamp solenoid. This opens the dump valve to vent a small
bulb during the START position). When the CAB amount of isolated rear brake pressure to an accumu
identifies a ground on this circuit, the CAB illumi lator. The action of fluid moving to the accumulator
nates the ABS warning lamp. reduces the isolated brake pressure at the wheel cyl
inders. The dump (pressure venting) cycle is limited
COMBINATION VALVE to very short time periods (milliseconds). The CAB
will pulse the dump valve until rear wheel decelera
Pressure Differential Switch tion matches the vehicle's deceleration rate or the
The pressure differential switch is connected to the desired slip rate programmed into the CAB. The sys
brake warning light. The switch is triggered by tem will switch to normal braking once wheel locking
movement of the switch valve. The purpose of the tendencies are no longer present.
switch is to monitor fluid pressure in the separate
front/rear brake hydraulic circuits.
A decrease or loss of fluid pressure in either DIAGNOSIS AND TESTING
hydraulic circuit will cause the switch valve to shut
tle forward or rearward in response to the pressure RWAL GENERAL DIAGNOSTIC INFORMATION
differential. Movement of the switch valve will push This section contains information necessary to
the switch plunger upward. This closes the switch diagnose the Rear Wheel Antilock (RWAL) brake sys
internal contacts completing the electrical circuit to tem. This section should be used to help diagnose the
^ the warning light. The switch valve may remain in following conditions:
an actuated position until repair restores system • Brake warning lamp (red) illuminated
pressures to normal levels. • ABS warning lamp (amber) illuminated
• Rear brakes lock-up on hard application
Metering Valve Diagnosis of base brake conditions which are obvi
The metering valve is used to balance brake action ously mechanical in nature should be directed to
between the front disc and rear drum brakes. The Group 5 Base Brake System in this Service Manual.
valve meters (holds-off) full apply pressure to the This includes brake noise, lack of power assist, park
front disc brakes until the rear brake shoes are in ing brake, or vehicle vibration during normal brak
full contact with the drums. The valve is designed to ing.
maintain front brake fluid pressure at 21-207 kPa Many conditions that generate customer com
(3-30 psi) until the hold-off limit of 807 kPa (117 psi) plaints may be normal operating conditions, but are
is reached. At. this point, the metering valve opens judged to be a problem due to not being familiar with
completely permitting full fluid apply pressure to the the RWAL system. These conditions can be recog
front disc brakes. nized without performing extensive diagnostic work,
given adequate understanding of the operating prin
RWAL SYSTEM OPERATION ciples and performance characteristics of the RWAL
During light ~ brake application, rear wheel. deceler system. See the RWAL Description and Operation
ation is not sufficient to activate the antilock system section in this group of the Service Manual to famil
components. Brake fluid applies pressure to the rear iarize yourself with the operating principles of the
wheels remains normal and is not modulated. How RWAL system.
ever, when braking effort, and rate of deceleration
approach programmed limits, sensor inputs will RWAL PERFORMANCE CHARACTERISTICS
cause the CAB module to activate the system.
Wheel/Tire Size And Input Signals
Normal Braking Mode Antilock system operation depends on accurate sig
In normal braking mode, the antilock solenoid nals from the rear wheel speed sensor. Ideally, the
valves are inactive. The valve is open and the dump vehicle's wheels and tires should all be the same size
valve is closed allowing normal fluid flow to the rear and type to ensure accurate signals and satisfactory
wheel cylinders. operation.
Antilock Braking Mode RWAL And Low Vehicle Speed

I f the CAB senses that rear wheel speed decelera The RWAL braking system will revert to normal
tion is excessive, i t will energize the isolation sole- braking and automatically turn off i f the vehicle is
moving less than a few mph. The lower limit at Stopping Distance
which RWAL is cancelled may be different depending The RWAL brake system limits wheel slip to
on tire and wheel diameters. Wheel lock-up may be approximately 20%. This provides. for maximum
noticed at the very end of an antilock stop and is con brake effectiveness. Wheel slip means how well the
sidered normal. tires grip the road surface. With light or no braking
there is no wheel slip. With the wheels locked (not
Distribution Of Braking Effects rotating) during a panic stop, there is 100% wheel
The RWAL system controls hydraulic pressure to slip. To obtain the shortest stopping distance and the
both rear wheels simultaneously, not each one inde greatest control over the vehicle during heavy brak
pendently. I f one rear wheel starts to decelerate too ing, approximately 20% wheel slip is most efficient,
rapidly, the RWAL system affects the hydraulic pres under most conditions.
sure to both rear brakes (Fig. 7).
Pedal Feel
In general, pedal feel will be similar to that of a
conventional vacuum boosted brake system. Under
certain conditions the pedal may drop slightly when
there is a need for pressure increase during a long
antilock stop. Remember, the sequence of antilock
events is to isolate, decrease, and then increase pres
sure to maintain brake effectiveness. At the point
when the system is in the increase mode is when the
pedal will drop slightly.
Tire Noise And Marks

Although the RWAL system prevents complete rear
wheel lock-up, some wheel slip is desired to obtain
LF LR optimum braking performance. During brake " pres
WHEEL WHEEL
sure modulation brake pressure is increased and
wheel slip controlled by the CAB is allowed to reach
up to approximately 20%. This means that the wheel
8020cd5a
rolling speed is approximately 20% less than that of
a free rolling wheel at any given vehicle speed. The
Fig. 7 RWAL Hydraulic Circuit
wheel slip may result in some tire "chirping",
Directional Stability depending upon the road surface. This sound should
Since the RWAL system operates on the rear not be interpreted as a total wheel lock-up and can
wheels only, i t is possible to lock the front wheels of be considered normal under most conditions.
the vehicle during a high deceleration stop. In this Complete wheel lock-up normally leaves a continu
event, the vehicle will be stable, but the driver will ous black tire mark on dry pavement. Antilock brak
be unable to alter the direction of the vehicle with ing will not leave a continuous black mark since the
the steering wheel (Fig. 8). wheel never reaches a totally locked condition. Tire
marks may be noticeable as light, patched marks on
the pavement.
Sound Level
The noise level of antilock braking is different from
normal braking. The noise level of a vehicle equipped
with ABS actually may be less during antilock brak
ing. Because the rear wheels never fully lock-up,
which would cause tire noise. Also, since the RWAL
brake system has no pump to produce noise that
might be associated with other antilock brake sys
tems, RWAL's ABS mode will be noticeably different.
8031e842
Vehicle Response In Antilock Mode

Fig. 8 Directional Stability
During antilock braking, the RWAL valve cycles
rapidly in response to CAB inputs. The driver may
experience a pulsing sensation in the brake pedal
BR BRAKES I -13
and vehicle as the valves modulate brake fluid pres
sure as needed. Brake pedal and vehicle pulsations FAULT
CODE
during an antilock stop should be considered as nor
NUMBER TYPICAL FAILURE DETECTED
mal.
RWAL SYSTEM SELF i J A I l O S T J C S 1 Not used.

The microprocessor in the CAB has both a self test
feature and a memory. The self test feature occurs 2 O p e n isolation v a l v e w i r i n g or b a d control
every time the ignition key is turned to the START module.
or RUN positions and continues as long as the igni

3 O p e n d u m p v a l v e w i r i n g or b a d control
tion is in the RUN position. During the self test, the
module.
microprocessor monitors and processes signals gener
ated by the systems inputs and outputs. I t also per 4 C l o s e d RWAL v a l v e switch.
forms a bulb check when the ignition key is first
turned to START or RUN which turns on the brake 5 O v e r 16 d u m p pulses g e n e r a t e d in 2 W D
warning lamp (red) and the ABS warning lamp v e h i c l e s (disabled for 4 W D ) .
(amber). I f the self test does not identify any mal
functions, both lamps will illuminate for a few sec 6 Erratic s p e e d sensor r e a d i n g w h i l e rolling.
onds and then go out.
I f a system fault is detected, the ABS warning 7 Electronic control m o d u l e fuse pellet o p e n ,
lamp and the brake warning lamp are illuminated. A isolation output missing, or v a l v e wiring
Diagnostic Trouble Code (DTC) is also stored in the shorted to ground.
microprocessor's memory. The DTC remains in mem

8 D u m p output missing or v a l v e wiring shorted to
ory even after the ignition key is turned to OFF with
ground.
the exception of codes 9 and 11 which are erased any
time the ignition key is turned to OFF. The memory 9 S p e e d sensor w i r i n g / r e s i s t a n c e (usually high
has the capability to store only one DTC at any given reading).
time. The problem that caused the DTC must be
repaired and the DTC erased before another code will 10 Sensor w i r i n g / r e s i s t a n c e (usually low reading).
appear (if any).
I f a system malfunction should occur, DO NOT 11 B r a k e switch a l w a y s o n . RWAL light c o m e s on
immediately replace the CAB. A blown system fuse, w h e n speed exceeds 40 mph.
poor ground, or loss of feed voltage will cause system
faults similar to a CAB failure. Never replace the • 12 Not used.
CAB unless the diagnostic procedure identifies
13 Electronic control m o d u l e p h a s e lock loop
a CAB replacement is necessary.
failure.
RWAL DIAGNOSTIC TROUBLE CODES

14 Electronic control m o d u l e program check
When a DTC is generated, the brake warning lamp failure.
and ABS warning lamp are illuminated. To retrieve a
DTC place the ignition key in the. RUN position. 15 Electronic control m o d u l e R A M failure.
Then momentarily ground pin 13 of the Data Link
Connector. When the ground is removed the ABS and J9005-101
Brake Warning Lamp will begin to flash.
The initial flash will be a long flash followed by Fig, 9 RWAL Diagnostic Trouble Codes
one or more short flashes. The long flash indicates Refer to the diagnostic test procedures in this sec
the beginning of the DTC number. The short flashes tion of the Service Manual for proper testing proce
are a continuation of the DTC number. You must dures.
count the long flash and short flashes for an
accurate trouble code number.When the DTC has Erasing Diagnostic Trouble Code From
been retrieved compare i t to the Diagnostic Trouble Memory
Code Chart (Fig. 9). To erase a DTC from the CAB's memory, battery
There may be a problem i f the brake warning lamp voltage must be removed from the CAB. To remove
and/or ABS lamp: battery voltage from the CAB, first turn the ignition
• Does not come on key to the OFF position. Then one of the following
© Is on all of the time
• Flashes incorrectly
5 - 54 BRAKES BR

methods can be used to remove the battery supply statement. The YES or NO columns will guide you to
voltage from the CAB. the next appropriate test.
• Disconnect CAB 14-way connector
• Disconnect battery ground connector Start - RWAL Diagnosis - Verifying the
• Remove CAB fuse from fuse box Customer's Concern
Start the engine and monitor the brake warning
ABS SERVICE PRECAUTIONS lamp and ABS warning lamp. Both lamps will illumi
The ABS uses an electronic control module, the nate for a few seconds when the ignition is turned
CAB. This module is designed to withstand normal on. I f the brake warning lamp and or ABS warning
current draws associated with vehicle operation. lamp remain illuminated or do not come on, continue
Care must be taken to avoid overloading • the CAB on to the RWAL DIAGNOSTIC TEST PROCEDURES
circuits. I n testing for open or short circuits, do TEST 1 section of this group. I f the warning lamps
not ground or apply voltage to any of the cir illuminate for a few seconds and then go out, proceed
cuits unless instructed to do so for a diagnostic with this test.
procedure. These circuits should only be tested With the engine running and the vehicle in PARK
using a high impedance multi-meter or the DRB or NEUTRAL, check the service brake. The brake
tester as described in this section. Power should pedal should remain firm under steady foot pressure
never be removed . or applied. to any control module and not travel too far towards the floor.
with the ignition in the ON position. Before removing The vehicle can be test driven i f is determined that
or connecting battery cables, fuses, or connectors, the. base brake system is functioning normally.. Refer
always turn the ignition to the OFF position. to the Base Brake Diagnose and Testing section in
this group of the Service Manual i f the previous
CAUTION: Use only factory wiring harnesses. Do checks determine a malfunction with the base
not cut or splice wiring to the brake circuits. The brakes.
addition of after-market electrical equipment (car
phone, radar detector, citizen band radio, trailer Test Driving RWAL Complaint Vehicle
lighting, trailer brakes, ect.) on a vehicle equipped Most RWAL complaints will require a test drive as
with antilock brakes may affect the function of the part of the diagnostic procedure. The purpose of the
antilock brake system. test drive is to duplicate and verify the customers
concern.
RWAL DIAGNOSIS WARNING: Reduced braking may be encountered if

An RWAL system malfunction will be indicated by the vehicle is test driven with either the brake warn
illumination of the ABS warning lamp. In most cases, ing lamp or the ABS warning lamp illuminated.
the brake warning lamp will also be illuminated at Extreme caution should be used.
the same time. I f either or both warning lamps illu
minate, the following six step troubleshooting proce Perform both normal and firm braking stops in the
dure should be implemented. 25-40 mph range. At least one complete ABS stop
• Verify the customer's concern should be performed. Determine i f there are any
• Determine any related symptoms unusual brake operating conditions such as vehicle
• Diagnose the concern lead during braking, brakes grabbing, brakes drag
9 Isolate the concern ging, noise, low brake pedal, etc. I f the brake warn
• Repair the concern ing lamp and or ABS warning lamps illuminate
• Verify the repair during the test drive, proceed to the RWAL DIAG
The RWAL diagnosis begins by verifying the cus NOSTICS PROCEDURES TEST 1 section in this
tomers concern. This test starts by verifying the ABS group. I f the vehicle leads during braking, the brakes
warning lamp and brake warning lamp operation. grab, the brakes are dragging, there is brake related
When this test is complete, you will be instructed to noise, a low brake pedal, etc., refer to the base brake
perform either RWAL DIAGNOSTIC PROCEDURES diagnosis section in this section of the Service Man
TEST 1 or RWAL DIAGNOSTIC PROCEDURES ual. I f the warning lamps remain extinguished and
TEST 2. The test usually will begin with a brief the brakes respond normally, then proceed to the
explanation of the procedure or provide guidelines for RWAL DIAGNOSTIC PROCEDURES TEST 2 section
the test. Then, you will begin with step 1. Each test in this group.
has four columns; STEP, ACTION, YES, and NO. You
will be guided through each test by the ACTION. The
ACTION questions will all have bullets (•) in front of
them. Answer all questions either with a YES or NO
BR BRAKES 5 -15
NOTE; If either warning lamp is illuminated, a DTC This procedure starts with the brake warning lamp
should have been generated. Certain DTCs are and/or ABS" warning lamp illuminated, flashing, or
erased when the ignition key is turned to OFF. Do not coming on at all. Do not attempt to perform this
not turn the ignition key OFF until you have test without first performing RWAL DIAGNOSIS. I f
recorded the DTC. Refer to RWAL SYSTEM SELF you have arrived at this' procedure from RWAL
DIAGNOSIS for instructions on retrieving any DTC. DIAGNOSIS, make sure you do not turn the ignition
key OFF prior to recording the DTC.
RWAL DIAGNOSTIC PROCEDURES—TEST 1

RWAL DIAGNOSIS must be performed before
beginning this diagnostic test procedure.
Step Action Yes No

1 RWAL DIAGNOSIS must be performed before Perform step 2. Perform RWAL
beginning this diagnostic test procedure. DIAGNOSIS.
• Has RWAL DIAGNOSIS test been performed?
2 The ignition switch should be in the run position prior Perform step 6. Perform step 3.
to starting.
© Are both brake warning and ABS warning lamps
illuminated?
3 © Is the ABS warning lamp illuminated only? Perform RWAL Perform step 4.
DIAGNOSTIC
PROCEDURES TEST
3.
4 © Is the brake warning lamp illuminated only? Perform RWAL Perform step 5.
DIAGNOSTIC
PROCEDURE TEST
4.
5 • Are either the brake warning lamp or ABS warning Perform step 11. Perform RWAL
lamp flashing? DIAGNOSTIC
PROCEDURES TES
5.
6 Check the RWAL system for a DTC. Refer to the Perform step 7. Perform RWAL
RWAL DIAGNOSTIC CONNECTOR LOCATION DIAGNOSTIC
section and the RWAL DIAGNOSTIC TROUBLE PROCEDURES TEST
CODES section in this group. Record the DTC 6.
before proceeding.
© Were you able to retrieve a DTC from the CAB's
memory?
7 • Was DTC 9 or 11 recorded? Perform RWAL Perform step 8.
DIAGNOSTIC
PROCEDURES TEST
7.
8 • Were you required to perform the Test Driving Perform RWAL Perform step 9.
RWAL Complaint Vehicle procedure prior to DIAGNOSTIC
beginning RWAL DIAGNOSTIC PROCEDURES PROCEDURES TEST
TEST 1? 7.
5 - 56 BRAKES BR
Step Action Yes No

9 To verify if the DTC is related to an intermittent fault, Perform RWAL Perform step 10.
the fault code should be erased from the CAB's DIAGNOSTIC
memory. Refer to the RWAL DIAGNOSTIC PROCEDURES TEST
TROUBLE CODE section of this group and erase 2.
the DTC.Turn the ignition key to the run position.
• Did both the brake warning lamp and ABS
warning lamp illuminate for a few seconds and then
go out?
10 Recheck the RWAL system for DTCs. Refer to the Perform RWAL The code that was
RWAL DIAGNOSTIC CONNECTOR LOCATION DIAGNOSTIC generated in step 6
section and the RWAL DIAGNOSTIC TROUBLE PROCEDURES TEST does not have
CODE section in this group. Record the DTC before 7. diagnostic priority over
proceeding. the DTC recorded in
• Did the same DTC that was recorded in step 6 this test. Perform
reappear? RWAL DIAGNOSTIC
PROCEDURES TEST
7 for the code
identified in this test
first, and then verify
the repair.
11 • Have you initiated the self diagnostic program? Record the DTC and Perform step 12.
perform step 7.
12 Turn the ignition key to the OFF position.Disconnect Perform step 13. Perform step 2.
the CAB 14-way connector and leave disconnected
for 5 seconds.Reconnect the CAB 14-way connector.
Turn the ignition switch to the RUN position.
• Is/are the warning lamp(s) still flashing?
13 Turn the ignition key to the OFF position. Disconnect Repair as necessary Perform step * *
and inspect the CAB 14-way connector for and perform the
indications of poor connections. Verification Test.
• Are there any connections that appear
inadequate?
14 Connect a voltmeter between terminal 3 and Perform step 15. Repair the ignition feea
ground.Turn the ignition key to the RUN circuit for an
position.Perform a wiggle test on the RWAL wiring intermittent connection
harness while observing the voltmeter. and perform the
• Did the voltage remain steady at 9 volts or Verification Test.
greater?
15 Turn the ignition key to the OFF position. Connect an Perform step 16. Repair the ground
ohmmeter between terminal 10 and ground. Perform circuit for an
a wiggle test on the RWAL wiring harness while intermittent connection
observing the ohmmeter. and perform the
© Is the resistance steady at less than 1 ohm? Verification Test.
16 Connect an ohmmeter between terminal 12 and Replace the RWAL Repair the diagnostic
ground.Perform a wiggle test on the RWAL wiring module and perform terminal circuit for an
harness while observing the ohmmeter. the Verification Test. . intermittent short to
• Is the resistance greater then 100K and steady? ground and perform
the Verification Test.
BR BRAKES 1 - 57
DIAGNOSIS AND T E S T I N G (Continued!
RWAL DIAGNOSTIC PROCEDURE—TEST 2 • Service brakes - apply the service brakes and
RWAL DIAGNOSIS must be performed before verify whether or not the pedal returns to its normal
beginning this diagnostic test procedure. height
This procedure is performed only when there is a • Suspension components - verify all suspen
customers's concern related to the RWAL system and sion components for proper installation
no DTC is recorded. • Brake lines and hoses - inspect all lines and
Your diagnostic test procedure must begin-with a hose for leaks and proper routing.
visual inspection of the following items. • RWAL related components, wiring, and con
• Brake fluid - verify proper level, condition, and nectors - Electrical connectors should be inspected
visually inspect for leaks around the master cylinder, for bent or expanded pins and terminals, broken or
hoses, lines, RWAL valve, calipers, and wheel cylin distorted locking tabs, damaged or missing weather
ders. seals, or pushed out wires (refer to section 8W in this
• Wheels and tires - inflate the tires to the rec Service Manual for proper location).
ommended tire pressures and verify that all tires are Once the visual inspection is completed, your next
of the same size step in the diagnostic sequence is to proceed to step 1
• P a r k i n g brake - verify proper' operation of the in the following table.
parking brake
Step Action Yes No

1 Apply the brakes and observe the stop lamps. • Did Perform step 2. Perform step 15.
the stop lamps illuminate while depressing the brake
pedal?
2 Release the brake pedal. Perform step 3. Perform step 6.
Are the stop lamps on all of the time?
3 Adjust the stop lamp switch. Apply and release the Perform step 4. Inspect the master
brakes. cylinder push rod and
• Did the brake pedal return to its proper position brake pedal arm pivot
when you released the brakes? for any binding. Repair
as necessary and
perform Verification
Test.
4 o Are the stop lamps still on all of the time? Perform step 5. Perform Verification
Test.
5 Inspect the wiring, connectors, and brake switch for Repair the short as Replace the brake
a short to battery voltage. necessary and perform switch and perform the
• Was there a short to battery voltage at the wiring, the Verification Test. Verification Test.
connectors, or brake switch?
6 Remove RWAL speed sensor from differential Perform step 7. Install a exciter ring
housing. Inspect the exciter ring. and perform
© Is the exciter ring present? Verification Test.
7 © Does the exciter ring have any missing teeth or is Replace the exciter Perform step 8.
cracked? ring and perform the
Verification Test.
8 Install speed sensor. Position vehicle on a hoist. Perform step 14. Perform step 9.
Raise rear wheels to safely clear the floor.Connect a
voltmeter to the RWAL rolls test connector.Set scale
to an AC voltage scale of approximately 2 volts.Start
the engine and rotate the wheels at approximately 5
mph. WARNING; WARNING: STAY CLEAR OF
ROTATING WHEELS
• is the voltage 650mv (rms) or greater?
5 - 58 BRAKES — — ~ BR
Step Action Yes No

9 Turn ignition key to the OFF position.Disconnect the Perform step 10. Perform Test 20.
14-way connector from the CAB.Connect a
ohmmeter across terminals 13 and 14 and measure
the resistance of the RWAL speed sensor circuit,
o Is the resistance 1750 ohms + or - 750 ohms?
10 Measure resistance from terminal 13 to a good Repair the RWAL Perform step 11.
chassis ground. speed sensor circuit
© Is the resistance less than 1000 ohms? for a short to ground
and perform the
Verification Test.
11 Measure resistance from terminal 14 to a good Repair the RWAL Perform step 12.
chassis ground. speed sensor circuit
© Is the resistance less than 1000 ohms? for a short to ground
and perform the
Verification Test.
12 Use the procedure "CHECKING RWAL SPEED Perform step 14. Perform step 13.
SENSOR AIR GAP" and verify the clearance
between the sensor and exciter ring.
• Is the clearance less than 0.050 in. and greater
than 0.005 in.?
13 • Was the dimension recorded from the RWAL Replace the exciter Replace the RWAL j
speed sensor underside flange to sensor pole piece ring or repair speed sensor and
between 1.07 - 1.08 in. (27.18 - 27.43 mm)? differential as required perform the Verification
and perform the Test.
Verification Test.
14 Inspect the rear brakes for mechanical problems Repair the rear brakes The RWAL brake
such as brakes grabbing, locking, or vehicle lead as necessary and system is operationa
during braking. perform the Verification at this time.
© Do the rear brakes have any mechanical Test.
problems?
15 Inspect the fuse that feeds the stop lamp switch. Perform step 16. Perform step 19.
® Is the fuse for the stop lamp switch functional?
16 Use a voltmeter and verify battery voltage supplied Perform step 17. Repair the open circuit
to the fuse. to the fuse and perform
® Is battery voltage supplied to the fuse? the Verification Test.
17 Use a voltmeter and verify that battery voltage is Adjust the stop lamp Repair the open circuit
supplied to the stop lamp switch for the stop lamp switch and perform from the fuse to the
circuit. step 18. stop lamp switch.
© Is battery voltage supplied to the stop lamp switch
for the stop lamps?
18 Verify if battery voltage is applied to the stop lamp Replace the stop lamp Repair the open circuit
circuit at the stop lamp bulb when the brakes are bulb(s) and perform as necessary and
applied. the Verification Test. perform the Verification
• Is battery voltage supplied to the stop lamp circuit Test.
at the stop lamp bulb when the brakes are applied?
BR — _ - _ _ _ _ - _ — _ _ _ _ _ — _ _ _ _ _ _ _ _ _ BRAKES 5 - 59
D I A G N O S E S AND T E S T I S ® ( C o n t i n u e d )
Step Action Yes 3

19 Inspect for the presence of any add-on (trailer) wiring Repair, remove, or Inspect the stop lamp
that may cause a short to ground. replace the wiring. switch wiring for any
© Is any additional wiring added to the vehicle that Replace the fuse. causes that may allow
may cause a short to ground? Perform the the fuse to blow.
Verification Test and Repair the short to
inform the customer of ground. Replace the
any alterations to their fuse. Perform the
add-on wiring. Verification Test.
20 Disconnect the 2-way rear WSS connector.Connect Perform step 21 Replace the RWAL
an ohmmeter across the terminals of the RWAL speed sensor and
speed sensor. perform the Verification
® Is the resistance 1750 ohms + or - 750 ohms? Test.
21 Connect an ohmmeter between terminal 13 of the Repair the RWAL Repair the RWAL
14-way CAB connector and terminal 1 of the RWAL speed sensor circuit speed sensor circuit for
speed sensor's connector. for an open or high an open or high
© Is the resistance less then 1 ohm? resistance between resistance between
terminal 14 of the CAB terminal 13 of the CAB
and terminal 2 of the and terminal 1 of the
RWAL speed sensor's RWAL speed sensor's
connector.Then, connector. Then,
perform the Verification perform the Verification
Test. Test.
CHECKING RWAL SPEED SENSOR AIR GAP should be a minimum of 0.127 mm (0.005 in.) and a
(1) Remove sensor from differential. maximum of 1.27 mm (0.050 in.).
(2) Measure and record the distance from the (5) I f air gap is not within stated limits, proceed
underside of the sensor flange to the end of the sen as follows:
sor pole piece (Fig. 10). This distance represents (a) Dimension B , distance should be between
dimension B. 27.18 - 27.43 mm (1.07 -1.08 in.). I f the RWAL
(3) Measure and record the distance between the speed sensor is not within these limits, replace the
sensor mounting surface of differential case and RWAL speed sensor.
teeth at top of the exciter ring (Fig. 10). This dis (b) Dimension A distance should be between
tance represents dimension A. 27.56 - 28.45 mm (1.085 - 1.120 in.). I f dimension A
(4) Subtract dimension B from dimension A to is not within the specification, replace the exciter
determine the RWAL speed sensor air gap. The gap ring or repair the differential.
S E N S O R MOUNTING F A C E SENSOR FLANGE
DIMENSION A
- DIMENSION B
DIMENSION C
DIMENSION B
SENSOR POLE
PIECE *
E X C I T E R RING 8020cdaf
Fig. 10 Checking RWAL Speed Sensor Air Gap

5 - 60 BRAKES

(c) I f dimension A and dimension B exceeds their did not illuminate the brake warning lamp when the
specifications, replace both the RWAL speed sensor ABS lamp was illuminated. During the test, the
and exciter ring. Also, repair the differential i f nec RWAL 14-way CAB connector will be disconnected.
essary. When the connector is disconnected, all DTCs stored
in memory will be erased. Prior to this test, retrieve
RWAL DIAGNOSIS PROCEDURES—TEST 3 and record all DTCs for future reference. Refer to the
The CAB illuminates the brake warning lamp any RWAL DIAGNOSTIC CONNECTOR LOCATION and
time i t illuminates the ABS warning lamp. This test the RWAL DIAGNOSTIC TROUBLE CODE section
is performed only to identify the reason why the CAB in this group
Step Action Yes No

1 With the ignition key in the RUN position, apply the Perform step 4. Perform step 2.
parking brake. © Did the brake warning lamp
illuminate?
2 Turn the ignition switch to the START position. Perform step 4. Perform step 3.
® Did the brake warning lamp illuminate while the
ignition switch was placed in the START position?
3 Remove the brake warning lamp bulb. Verify the bulb Perform step 6. Replace the bulb and
is not burned out or damaged. restart the test at the
• Is the bulb functional? RWAL DIAGNOSIS
section.
4 Disconnect the RWAL 14-way connector and the Perform step 5. Repair the open circuit
connector to the brake warning lamp bulb. Refer to between the RWAL
section 8W for proper brake warning lamp wiring. 14-way connector and
Connect an ohmmeter between terminal 5 of the the brake warning
RWAL 14-way connector and the brake warning lamp. Once the repair
lamp bulb's ground circuit. Refer to section 8W for is complete, restart the
proper brake warning lamp wiring. test at the RWAL
© Is there continuity between the brake warning DIAGNOSIS section.
lamp bulb's ground circuit and terminal 5 of the
RWAL 14-way connector?
5 Inspect the RWAL 14-way CAB connector. Repair as necessary Replace the CAB and
© Are there any terminals that are bent, expanded, and restart the test at perform the Verification
broken? Are the locking tabs functional? Are any the RWAL Test.
wires pushed out from the connector? DIAGNOSIS section.
6 Inspect the connector to the brake warning lamp Repair as necessary Replace the message
circuit. Refer to section 8W for proper brake warning and restart the test at center or instrument
lamp wiring. the RWAL cluster as required and
© Are there any terminals that are bent, expanded, DIAGNOSIS section. restart the test at the
broken? Are the locking tabs functional? Are any RWAL DIAGNOSIS
wires pushed out from the connector? section.
BR BRAKES 5 - 61
RWAL DIAGNOSTIC PROCEDURES—TEST 4 test verifies whether the parking brake switch is the
This test has only the brake warning lamp illumi only cause for brake warning lamp illumination or
nated. Except for the parking brake switch, all other there is a malfunction with the ABS warning lamp
brake warning lamp switched ground circuits will circuit.
cause the ABS warning lamp to illuminate also. This
Step Action Yes No

1 Turn the ignition key OFF Turn the ignition key to Perform step 2 Perform step 6.
the RUN position. • Did the ABS warning lamp
illuminate for a few seconds and then extinguish?
2 Release the parking brake. System is operating Perform step 3.
e Did the brake warning lamp extinguish? normally
3 Pull the parking brake release handle and pull the Perform step 4. Perform step 5.
parking brake pedal upward. Verify the operation of
the parking brake mechanism.
© Were you able to pull the pedal up any higher?
4 © Did the brake warning lamp extinguish when the Repair the parking Repair the parking
parking brake was released fully? brake system as brake system as
necessary. necessary then,
perform step 5.
5 Turn the ignition key to the OFF position. Disconnect Repair the brake Replace the CAB and
the CAB 14-way connector. warning lamp ground perform the Verification
WARNING: NOTE: Vehicles with diesel engines control circuit for a Test.
must also have the vacuum sensor short to ground and
disconnected.Turn the ignition key to the RUN perform the Verification
position. Test.
• Is the brake warning lamp illuminated?
6 ® Is the ABS warning lamp illuminated continuously? Perform RWAL Perform step 7.
DIAGNOSTIC
PROCEDURES TEST
1.
7 Inspect the CAB 14-way connector. Perform step 8 Reconnect and perform
© Is the connector properly connected to the CAB? the Verification Test.
8 Inspect the wiring and terminals at the connector. Repair as necessary Perform step 9.
© Are the terminals or wiring pushed out or and perform the
damaged? Verification Test.
9 Connect an ohmmeter to terminal 10 and a good Perform step 10 Repair the ground
chassis ground. circuit and perform the
© Is the resistance to ground less than 1 ohm? Verification Test.
10 Connect a voltmeter to terminal 2 and a good Perform step 11. Replace the CAB and
chassis ground. Turn the ignition key to the RUN perform the Verification
position. Test.
© Is the voltage less than 9 volts?
11 Inspect the ABS warning lamp bulb. Repair the open circuit Replace the bulb and
© Is bulb functional? from terminal 2 to the perform the Verification
ABS warning lamp and Test.
perform the Verification
Test.
5 - 62 BRAKES BR
RWAL DIAGNOSTIC PROCEDURES—TEST 5 minated during the CRANKING bulb check. I f either
This procedure starts with neither the brake warn- lamp illuminated during the bulb check, then per-
ing lamp illuminated nor the ABS warning lamp illu- form RWAL DIAGNOSTIC PROCEDURES TEST 1
Step Action Yes

1 In most cases, the fuse that feeds the brake warning Perform step 2 Inspect and repair the
lamp also feeds the A B S warning lamp. Inspect the warning lamp circuit for
fuse that feeds the warning lamp circuit. • Is the a short to ground and
fuse functional? replace the fuse, then
Test.
2 Turn the ignition key to the RUN position.Use a Perform step 3. Repair the open circuit
voltmeter and verify battery voltage supplied to the to the fuse and perform
fuse. the Verification Test.
© Is battery voltage supplied to the fuse?
3 Apply the parking brake. Repair the open circuit Repair the open circuit
• Did the brake warning lamp illuminate? from the ignition switch from the fuse to the
START circuit (ground warning lamp circuit
side during cranking) and perform the
to the brake warning verification Test.
lamp, then perform
RWAL DIAGNOSIS.
RWAL DIAGNOSTIC PROCEDURES—TEST 6 are able to retrieve a DTC from the CAB's memory,
This procedure starts with both the brake warning then perform RWAL DIAGNOSTIC PROCEDURES
lamp illuminated and ABS warning lamp illuminated TEST 1.
and RWAL diagnostics cannot be performed. I f you
Step Action Yes No

1 Turn the ignition key to the OFF position. Disconnect Perform step 2 Perform step 8.
the 14-way RWAL CAB connector.Turn the ignition
key to the RUN position. • Is the brake warning
lamp illuminated?
2 Inspect the level of brake fluid in the master cylinder Perform step 3. Find and repair cause
reservoir. of leakage then
Is the fluid level correct? perform the Verification
Test.
3 • Is the vehicle equipped with a diesel engine? Perform step 5. Perform step 4.
4 Disconnect the harness connector from the Repair the short to The pressure
differential pressure switch ground for the brake differential switch has
© Is the brake warning lamp still illuminated? warning lamp circuit shuttled. Check the
and perform the brake system for air in
Verification Test. the hydraulic circuit or
• possible mechanical
damage. Repair as
necessary and then
Test.
5 Start the engine. Perform step 6. Perform step 8.
© Is the brake warning lamp still illuminated?
BR •— BRAKES 5 - 63
Step Action Yes ->
6 Turn the engine OFF.Turn the ignition key to the Perform step 4. Perform step 7.
RUN position.Disconnect the harness connector from
the diesel vacuum warning switch.
© Is the warning lamp still illuminated?
7 Disconnect the vacuum hose from the diesel vacuum Replace the diesel Repair the vacuum
warning switch and connect a vacuum gauge to the vacuum warning supply as required and
hose. Start the engine. switch and perform the perform the Verification
• Is there an adequate supply of vacuum to the Verification Test. Test.
warning switch?
8 Turn the ignition key to the OFF position.Connect a Perform step 9. Repair the open circuit
ohmmeter across terminal 12 to the terminal in the between the CAB's
diagnostic test connector. 14-way connector and
• Is the resistance less than 1 ohm? the diagnostic terminal
then perform RWAL
DIAGNOSIS.
9 With the ohmmeter still installed in terminal 12 of the Repair the short to Perform step 10.
CAB's 14-way connector, install the other end of the ground of the
ohmmeter to ground. diagnostic terminal
• Is the resistance less than 1 ohm? circuit and perform the
verification test.
10 Install a voltmeter between terminal 3 of the CAB's Perform step 11. Perform step 13.
14-way connector and ground.Turn the ignition key
to the RUN position.
• Is the voltage greater than 9 volts?
11 Install a voltmeter between terminal 9 of the CAB's Perform step 12. Perform step 14.
14-way connector and ground.
Is the voltage greater than 9 volts?
12 Inspect the CAB's 14-way connector. Repair as necessary Replace the CAB and
© Are there any bent terminals, terminals that are and perform the perform the Verification
pushed out, terminals that are corroded, a locking Verification Test. Test.
tab that is damaged or pins that are bent on the
CAB?
13 Inspect the fuse that feeds the ignition circuit of the Repair the open circuit Repair the short to
CAB. to terminal 3 of the ground, replace the
• Is the fuse functional CAB's 14-way fuse, and then perform
connector and perform the Verification Test.
14 Inspect the fuse that feeds the battery feed circuit of Repair the open circuit Repair the short to
the CAB. to terminal 9 of the ground, replace the
• Is the fuse functional CAB's 14-way fuse, and then perform
connector, and perform the Verification Test.
5 - 64 BRAKES BR
RWAL DIAGNOSTIC PROCEDURES—TEST 7 An intermittent DTC can be tested i n the same

This test begins with a DTC that can be regener manner as DTCs that are reoccurring. The only dif
ated anytime the CAB memory is cleared. You can ference is usually an intermittent DTC will have a
begin your diagnosis by locating the recorded DTC i n malfunction with either a poor electrical connection
the chart below. A brief description follows the code. or have a problem with the wiring. Never replace the
The final column provides a list of circuits and com CAB for an intermittent DTC unless otherwise told
ponents to test along with specifications and values. to do so.
Once y o u r diagnosis is complete, perform the
V E R I F I C A T I O N TEST.
DTC DTC DESCRIPTION DIAGNOSIS

1 DTC 1 is not a fault code and Attempt to retrieve the DTCs again.If DTC 1 appears again, perform
should not occur. step 12 of the RWAL DIAGNOSTIC PROCEDURES TEST t .If not,
record the DTC and start at the appropriate test.
2 This code identifies a open in the Components and circuits involved include: © Open circuit from
isolation valve circuit. terminal 1 of the 14-way connector to the RWAL valve.
© Ground connection for the RWAL valve.
© Open circuit in the RWAL valve's isolation solenoid.
© Poor connections in the 14-way CAB connector.
• Poor connections in the RWAL valve's 4-way connector.
• CAB.
Check resistance of the isolation solenoid and circuit. Resistance of the
solenoid should be approximately 3-6 ohms.
3 This code identifies an open in the Components and circuits involved include:
dump valve circuit. o Open circuit from terminal 8 of the 14-way connector to the
RWAL valve.
• Ground connection for the RWAL valve.
• Open circuit in the RWAL valve's dump solenoid.
• Poor connections in the 14-way CAB connector.
• Poor connections in the RWAL valve's 4-way connector.
• CAB.
Check resistance of the dump solenoid and circuit. Resistance of the
4 This code identifies a short in the Components and circuits involved include:
reset switch circuit. © Short circuit from terminal 11 of the 14-way connector to the
RWAL valve.
© Short circuit in the RWAL valve's reset switch.
• CAB.
Check resistance of the reset switch circuit and ground. Resistance of
the circuit to ground should be over 10,000 ohms.
5 This code identifies that over 16 Components and circuits involved include:
dump pulses occurred during an © Open circuit from terminal 4 of the 14-way connector to the 4X4
antilock stop.This code only switch (fault may have occurred in 4WD mode)
affects 2WD vehicles and 4WD © Mechanical malfunction in the rear brakes (brakes may be
vehicles while in 2WD mode. 4WD locking-up).
vehicles use the 4WD switch to • RWAL valve.
disable the diagnostics. During an
antilock stop, a vehicle in 4WD
mode may normally have 16
dump pulses.
BR BRAKES 5 - 65

6 This code identifies an erratic rear Components and circuits involved include:
wheel speed sensor reading.This • Intermittent poor connection between terminals 13 and 14 of the
code can only be recorded by the 14-way connector and the RWAL WSS.
CAB while the CAB is monitoring • Build-up of foreign material on the tip of the RWAL WSS.
a speed senor that identifies the • Exciter ring - broken, chipped teeth, teeth that are missing,
vehicle is moving. exciter ring that is bent.
• RWAL WSS.
• CAB.
The RWAL WSS can be tested by connecting a voltmeter into the RWAL
WSS circuit. Set the voltmeter to the AC scale. Then, rotating the rear
wheels (both wheels must be rotated at same speed and in same
direction) at 5 mph. The RWAL WSS should produce a voltage of at
least 650 mv (rms) and should be steady.
isolation valves circuit. • Short to ground from terminal 1 in the 14-way connector to the
RWAL valve.
© Short in the RWAL valve's isolation solenoid.
• CAB.
Check resistance of the isolation solenoid and circuit. Resistance of the
WARNING: CAUTION: I t I s important to r e m e m b e r t h a t the short
to ground m u s t be r e p a i r e d prior t o i n s t a l l i n g a CAB for t h i s DTC.
dump valve circuit. • Short to ground from terminal 8 in the 14-way connector to the
RWAL valve.
© Short in the RWAL valve's dump solenoid.
• CAB.
Check resistance of the dump solenoid and circuit. Resistance of the
WARNING: CAUTION: It is important to remember that the short
to ground m u s t be repaired p r i o r to i n s t a l l i n g a CAB for this DTC.
9 This code usually identifies an Components and circuits involved include:
open in the RWAL WSS circuit. ® Open circuit between terminals 13 and 14 and the RWAL WSS
• Poor connection in the 14-way connector.
• Poor connection at the RWAL WSS.
• RWAL WSS.
• CAB.
The RWAL WSS should have a resistance between 1000 and 2500
ohms.
10 This code usually identifies a short Components and circuits involved include:
in the RWAL WSS circuit. © Short circuit between terminals 13 and 14 and the RWAL WSS
© Short circuit between terminals 13 and 14, the RWAL WSS and a
ground.
• RWAL WSS.
• CAB.
The RWAL WSS should have a resistance between 1000 and 2500
ohms.
5 - 66 BRAKES — — BR

11 This code indicates the CAB Components and circuits involved include:
sensed the brakes being o n for an © Open circuit from terminal 7 to the stop lamp switch
extended length of time with the © Poor connection in the 14-way connector.
vehicle exceeding 4 0 mph. © Poor connection in the stop lamp switch connector.
• Open circuit from stop lamp switch to ground.
o Mis-adjusted stop lamp switch.
o Stop lamp switch.
• CAB.
The stop lamp switch provides a path to ground when the brakes are
released. When the brakes are applied, the path to ground is
interrupted.
12 This code is not used Attempt to retrieve the DTCs again.
13 This code identifies that the CAB The CAB is the only component that will affect this DTC.
had a phase lock loop failure.
had a program check failure.
had a RAM failure.
>16 There are no DTC greater than Attempt to retrieve the DTCs again.
15.
RWAL VERIFICATION TEST S E R V I C E PR©©EBtJftES

The verification test will require a test drive as
part of the diagnostic procedure. The purpose of the RWAL BRAKE BLEEDING
test drive is to duplicate and verify the previous con RWAL brake bleeding can be performed manually,
dition. or with vacuum/pressure equipment. Refer to the
vacuum and pressure bleeding information in this
WARNING: Reduced braking may be encountered if section.
the vehicle is test driven with either the brake warn Bleed only one brake component at a time. Recom
ing lamp or the ABS warning lamp illuminated. mended bleed sequence is:
Extreme caution should be used. • master cylinder
• combination valve
Perform both normal and firm braking stops in the
• rear antilock valve
25-40 mph range. At least one complete ABS stop
• left rear wheel
should be performed. Determine i f there are any
• right rear wheel
unusual brake operating conditions such as vehicle
• right front wheel
lead during braking, brakes grabbing, brakes drag
• left front wheel
ging, noise, low brake pedal, etc. I f the brake warn
Use Mopar DOT 3 brake fluid, or an equivalent
ing lamp and/or the ABS warning lamps illuminate
meeting SAE J1703-F and DOT 3 standards, to fill
or flash during the test drive, proceed to the RWAL
and bleed the system.
DIAGNOSTICS PROCEDURES TEST 1 section in
Use a bleed hose at each caliper/cylinder bleed
this group. I f the warning lamps remain extin
screw. Attach one end of the hose to the bleed screw
guished and the brakes respond normally, then the
and insert the opposite end i n glass container par
previous malfunction has successfully been repaired
tially filled with brake fluid. A glass container makes
and the vehicle can be returned to the customer.
it easier to see air bubbles as they exit the bleed
hose. Be sure the end of the bleed hose remains
NOTE: If either warning lamp is illuminated, a DTC
immersed in fluid. This prevents air from' being
may have been generated. Restart your diagnosis at
drawn back into the system.
the RWAL DIAGNOSTIC PROCEDURES TEST 1. Cer-
Do not allow the master cylinder to run out of fluid
tain DTCs are erased when the ignition key is
when bleeding the brakes. An empty cylinder will
turned to OFF, Do not turn the ignition key OFF
allow air to be drawn back into the system. Check
until you have recorded the P T C
fluid level frequently during bleeding operations.
BR BRAKES 5 - 67
Be sure to tighten each brake line fitting, or bleed (2) Disconnect lines to front and rear brakes from
screw once bleeding is completed. Loose fittings and RWAL and combination valves (Fig. 12).
bleed screws allows air to enter the system.
Vacuum Bleeding
If vacuum bleeding equipment is being used, it is
not necessary to hold the front brake metering valve
open. Simply bleed the brakes following the bleed
equipment manufacturers instructions.
Pressure Bleeding
If pressure bleeding equipment will be used, the
front brake metering valve will have to be held open
to bleed the front brakes. The valve stem is located
in the forward end of the combination valve. The
stem must either be pressed inward, or held outward
slightly, a spring clip tool or helper is needed to hold
the valve stem in position.
Follow the manufacturers instructions carefully
when using pressure equipment. Do not exceed the
tank manufacturers pressure recommendations. Gen
erally, a tank pressure of 15-20 psi is more than suf
ficient for bleeding purposes. FRONT
Fill the bleeder tank with recommended fluid and BRAKES J9405-82
purge air from the tank lines before bleeding.
Do not pressure bleed without a proper master cyl Fig. 12 Master Cylinder brake lines
inder adapter. The wrong adapter can lead to leak (3) Remove brake lines connecting master cylinder
age, or drawing air back into the system. to combination valve.
Make sure the front brake metering valve in the (4) Remove nuts attaching master cylinder and
combination valve is held open. A spring clip tool is combination valve bracket to booster studs.
best for securing the valve stem in an open position. (5) Remove master cylinder.
(6) Remove combination valve, valve bracket and
REMOVAL AND INSTALLATION RWAL valve as assembly.
(7) Remove brake line connecting combination
RWAL VALVE/COMBINATION VALVE valve to RWAL valve.
(8) Remove bolt attaching RWAL valve to combina
REMOVAL tion valve bracket (Fig. 13). Then separate RWAL
(1) Disconnect ground wire and harness wires from valve from bracket.
combination valve switch and RWAL valve (Fig. 11).
INSTALLATION
(1) Install RWAL valve on combination valve
bracket. Do not tighten RWAL valve bolt completely
at this time.
(2) Install short brake line that connects RWAL
valve to combination valve. Tighten line fittings to
16-23 N-m (140-200 in. lbs.).
(3) Tighten RWAL valve attaching bolt to 23-34
N-m (200-300 in. lbs.).
(4) Install master cylinder on booster mounting
studs.
(5) Attach antilock harness ground wire to combi
nation valve bracket.
(6) Install combination valve bracket on booster
mounting studs and against master cylinder.
(7) Loosely install nuts that retain master cylinder
and combination valve on booster studs.
Fig. 11 Valve Harness
5 - 68 BRAKES BR
(2) Remove module lower attaching screws (Fig.
15). Screws are partially hidden by air duct but can
be removed with long shank, number 2 Phillips
screwdriver as shown.
Fig. 15 RWAL Module Lower Attaching Screws
Fig. 13 RWAL Valve/Combination Waive (3) Remove module upper attaching screw (Fig.
16).
(8) Install and connect all remaining brake lines.
Tighten line fittings to 16-23 N-m (140-200- in. lbs.).
(9) Connect harness wires to RWAL valve and to
combination valve switch.
.RWAL CONTROLLER
The RWAL electronic control module is located
under the central portion of the instrument panel. I t
is mounted on a bracket attached to the back side of
the panel. The module is accessible through an open
ing created by removal of the knee bolster.
REMOVAL
(1) Remove screws from knee bolster attached to
panel flange (Fig. 14).
Fig. 16 RWAL Module Upper Attaching Screw

(4) Remove module and bracket from underside of
instrument panel.
(5) Disconnect harness wires from module.
(6) I f module is to be replaced, remove module
from bracket. However, i f module is only being
removed for access to another component, leave mod
ule in place on bracket.
INSTALLATION
(1) Install module on mounting bracket, i f
removed.
(2) Connect harness wires to module.
(3) Position module and bracket on instrument
panel and install attaching screws.
Fig. 14 Knee Bolster (4) Install knee bolster.
BR BRAKES 5 - 69
REMOVAL AND INSTALLATION ( C o n t i n u e d )
REAR WHEEL SPEED SENSOR

RRAINING . &k
REMOVAL SCREW
(1) Raise vehicle on hoist. CABLE- """""
(2) Clean sensor, cover and sensor mounting area
of axle housing (Fig. 17). CLAMP-—"
(3) Disconnect harness wires from sensor (Fig. 17). BRAKE —
UNE
(4) Remove screw that secures brake cable, brake
line, sensor cover and sensor i n axle housing. COVER-
(5) Remove sensor and cover.
SENSOR- "
(6) Cover sensor opening in axle housing to pre j 1
vent dirt entry. AXLE .—-

HOUSING i S ^ I ^
INSTALLATION
(1) Insert sensor in axle housing opening.
(2) Position cover over sensor and install cover and
sensor attaching screw and tighten to 24 N-m (18 ft.
lbs.).
(3) Connect harness wires to sensor and lower
vehicle.
(4) Lower vehicle.
EXCITER RING
The * exciter ring is mounted on the differential
case. I f the ring is damaged refer to Group 3 Differ
ential and Driveline for service procedures.
J9405-80
Fig. 17 Rear Wheel Speed Sensor Mounting

SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
RWAL Valve
Mounting Bolt 23-34 N-m (200-300 in. lbs.)
Brake Lines 16-23 N-m (140-200 in. lbs.)
Wheel Speed Sensor
Rear Mounting Bolt 24 N-m (212 in. lbs.)
5 - 70 BRAKES BR
FOUR WHEEL ANTILOCK BRAKE SYSTEM
INDEX
page page
GENERAL INFORMATION REMOVAL AND INSTALLATION

ABS BRAKES COMPONENTS 70 CONTROLLER ANTILOCK BRAKE (CAB) . . 75
DESCRIPTION AND OPERATION EXCITER RING . 77
ABS RELAYS 72 FRONT SPEED SENSOR . . . . . . . . . . . . . . . . . . 76
ABS WARNING LAMP 72 FRONT TONE WHEEL 77
ALL WHEEL ANTILOCK BRAKE SYSTEM (ABS) . 70 FRONT WHEEL SPEED SENSOR (4WD) . . . . . . 76
COMBINATION VALVE 72 HYDRAULIC CONTROL UNIT/CONTROLLER
CONTROLLER ANTILOCK BRAKES (CAB) 71 ANITLOCK BRAKE 75
HYDRAULIC CONTROL UNIT (HCU) 71 REAR WHEEL SPEED SENSOR 77
WHEEL SPEED SENSOR (WSS) 72 RWAL VALVE/COMBINATION VALVE 74
DIAGNOSIS AND TESTING SPECIFICATIONS
ANTILOCK BRAKES 72 TORQUE CHART 77
SERVICE PROCEDURES SPECIAL TOOLS
ABS BRAKE BLEEDING 72 ABS BRAKES 78
GENERAL INFORMATION braking. The valves are operated by the antilock elec
tronic module.
ABS BRAKES COMPONENTS The antilock electrical system is separate from
The following is a list of components used in the other electrical circuits in the vehicle. A specially pro
All Wheel Antilock Brakes System (ABS). It consists grammed electronic control module is used to operate
of the standard Rear Wheel Antilock brake compo the system components.
nents, plus the parts needed for ABS. The pump/motor assembly on the front antilock
• Controller Antilock Brake (CAB) valve provides the fluid volume needed during
• Hydraulic Control Unit (HCU) antilock braking. The pump is operated by an inte
• Wheel Speed Sensor (WSS) gral electric motor. The DC type motor is controlled
• Rear Antilock Valve by the Controller Antilock Brake (CAB).
• Combination Valve
• Front Tone Rings NOTE: For additional information refer to the
• Rear Exciter Ring Antilock Brake Section in Group 8W. For test proce
dures refer to the Chassis Diagnostic Manual.

Normal Braking Mode
ALL WHEEL ANTILOCK BRAKE SYSTEM (ABS) The ABS electronic control module monitors wheel
The ABS system is designed to prevent wheel speed sensor inputs continuously while the vehicle is
lock-up during braking under virtually any road sur in motion. The module will not activate the ABS sys
face conditions. This allows the driver to retain tem as long as sensor inputs indicate normal brak
greater control of the vehicle during braking. ing.
The ABS system is a three channel design (Fig. 1). During normal braking, the master cylinder, power
The front brake antilock valve provides two channel booster and wheel brakes units all function as they
pressure control of the front brakes. Each front wheel would in a vehicle without ABS. The solenoid valves
brake unit is controlled separately. Two solenoid are not activated.
valves are used in each control channel.
Antilock Braking Mode
The rear brake antilock valve controls the rear
The wheel speed sensors converts wheel speed into
wheel brakes in tandem. The rear brake valve con
electrical signals. These signals are transmitted to
tains two solenoid valves.
the module for processing and determine wheel
The front and rear antilock valves contain electri
lock-up and deceleration rate. When a wheel speed
cally operated solenoid valves. The solenoid valves
modulate brake fluid apply pressure during antilock
BR BRAKES I - 71
DESCRIPTION AND OPERATION {Continued)

POWER
BRAKE
BOOSTER
FRONT
ANTILOCK
VALVE
RF RR
WHEEL WHEEL
LR
WHEEL
J9305-113
Fig. 1 ABS Hydraulic System

sensor signal indicate the onset of wheel lock-up the HYDRAULIC CONTROLLER
ABS braking is activated. CONTROL UNIT ANTILOCK B R A K E S
The antilock system retards the lockup conditions
DRIVER
by modulating fluid apply pressure to the wheel
SIDE
brake units. The pressure is modulated according to FENDER
wheel speed, degree of lock-up and rate of decelera PANEL
tion.
The solenoid valves are cycled continuously to mod
ulate pressure. Solenoid cycle time in antilock mode
can be measured in milliseconds.
CONTROLLER ANTILOCK BRAKES (CAB)

The CAB is located at the drivers inner fender
panel. The CAB is attached to the forward side of the
Hydraulic Control Unit mounting bracket (Fig. 2).
The CAB is used to monitor and operate the ABS
system. I t monitors the brake switch and wheel RWAL
speed sensors inputs to prepare for possible antilock VALVE 80315898
braking. The CAB controls the antilock valve sole
noid operation during all phases of antilock braking. Fig. 2 Controller Antilock Brakes and Hydraulic
Control Unit
HYDRAULIC CONTROL UNIT (HCU)
channel controls the right front brake unit. Each
The HCU mounted on the driver side inner fender front brake unit is controlled independently.
panel (Fig. 2). The solenoid valves are cycled open and closed as
The HCU consist of the front antilock valve assem needed during antilock braking. They are cycled rap
bly and pump/motor unit. idly and continuously to modulate brake fluid pres
FRONT ANITLOCK VALVE
sure and control wheel lock-up and deceleration.
The front brake antilock valve consists of a sole PUMP/MOTOR
noid valve body. The antilock valve provides two The pump is run by a DC type motor controlled by
channel pressure control of the front brakes. One the Controller Antilock Brake (CAB). The pump sup
channel controls the left front brake unit. The second plies the additional fluid volume needed during
antilock braking.
5 - 72 BRAKES BR
WHEEL SPEED SENSOR (WSS) The second relay is the ASB main (pump) relay.
The ABS brake system uses 3 wheel speed sensors. This relay is used to supply voltage to the ABS pump
A sensor is mounted to each front steering knuckles. motor, Front Antilock Valve and Rear Wheel Antilock
The third sensor is mounted on top of the rear axle Valve.
differential housing. The sensor is a magnet coil that Both relays are located in the engine compartment
is mounted over a tone wheel front/exciter ring rear in the Power Distribution Center.
with an air gap between them.
The sensors measure the wheel speed by monitor ABS WARNING LAMP
ing the rotation of the tone wheels front/exciter ring The amber ABS warning lamp i n located in the
rear. As the teeth of the tone wheels front/exciter vehicle instrument cluster. The ABS warning lamp
ring rear move through the magnetic field of the sen relay completes the circuit for the lamp by providing
sor an AC voltage is generated. This signal frequency a ground. The CAB checks the warning lamp at the
increases or decreases proportionally to the speed of beginning of each ignition cycle by turning on the
the wheel. The CAB monitors these signals for lamp for 3.4 seconds. The lamp is used to alert the
changes in wheel deceleration, i f the CAB detects a driver i f a malfunction i n the ABS system has
sudden wheel or wheels deceleration within a prede occurred by turning the lamp on steady.
termined amount the CAB will activate the ABS sys
tem.
COiBiNATiON ¥ A L ¥ E
ANTILOCK BRAKES
Pressure Differential Switch The ABS brake system performs several self-tests
The pressure differential switch is connected to the every time the ignition switch is turned on and the
brake warning lamp. The switch is triggered by vehicle is driven. The CAB monitors the systems
movement of the switch valve. The purpose of the * input and output circuits to verify the system is oper
switch is to monitor fluid pressure in the separate ating correctly. I f the on board diagnostic system
front/rear brake hydraulic circuits. senses that a circuit is malfunctioning the system
A decrease or loss of fluid pressure in either will set a trouble code i n its memory.
hydraulic circuit will cause the switch valve to shut
NOTE: The MDS or DRB III scan tool is used to
tle forward or rearward in response to the pressure
diagnose the ABS system. For additional informa
differential. Movement of the switch valve will push
tion refer to the Antilock Brake section in Group
the switch plunger upward. This closes the switch
8W. For test procedures refer to the Chassis Diag
internal contacts completing the electrical circuit to
nostic Manual.
the warning lamp. The switch valve may remain in
an actuated position until repair restores system
pressures to normal levels.
SERVICE PROCEDURES
Metering Valve
The metering valve is used to balance brake action ABS BRAKE BLEEDING
between the front disc and rear drum brakes. The ABS brake bleeding can be performed manually, or
valve meters (holds-off) full apply pressure to the with vacuum/pressure equipment. Refer to the vac
front disc brakes until the rear brakeshoes are i n full uum and pressure bleeding information in this sec
contact with the drums. The valve is designed to tion.
maintain front brake fluid pressure at 21-207 kPa Bleed only one brake component at a time. Recom
(3-30 psi) until the hold-off limit of 807 kPa (117 psi) mended bleed sequence is:
is reached. At this point, the metering valve opens • master cylinder
completely permitting full fluid apply pressure to the • combination valve
front disc brakes. • rear antilock valve
© front antilock valve
A I S RELAYS • left rear wheel
Two relays are use on the ASB system. An ABS • right rear wheel
warning lamp relay is used to activate the amber • right front wheel
ABS warning lamp. When the lamp is, lit the voltage • left front wheel
at the CAB monitoring point will be 0 volts. The volt Use Mopar DOT 3 brake fluid, or an equivalent
age at the monitoring point will be 12 volts when the meeting SAE J1703-F and DOT 3 standards, to fill
CAB energizes the relay turning the ABS lamp off. and bleed the system.
BR BRAKES 5 - 73

Use a bleed hose at each caliper/cylinder bleed valve stem is correctly unseated (pressed inward) by
screw. Attach one end of the hose to the bleed screw tool.
and insert the opposite end in glass container par (6) Stroke brake pedal rapidly 5-10 times. This
tially filled with brake fluid. A glass container makes action will fill upper and lower sections of valve rap
it easier to see air bubbles as they exit the bleed idly.
hose. Be sure the end of the bleed hose remains (7) Bleed new valve assembly at each brakeline fit
immersed in fluid. This prevents air from being ting one at a time. Remember to close valve bleed
drawn back into the system. plug before each brake pedal stroke. Continue bleed
Do not allow the master cylinder to run out of fluid ing until fluid flowing from fittings is clear and free
when bleeding the brakes. An empty cylinder will of bubbles.
allow air to be drawn back into the system. Check (8) Remove depressor tool from valve stem and
fluid level frequently during bleeding operations. install cap on stem. Then tighten bleed plug to 7-9
Be sure to tighten each brakeline fitting, or bleed N-m (60-84 in. lbs.).
screw once bleeding is completed. Loose fittings and
BLEED
bleed screws allow air to enter the system. VALVE
STEM
ABS MANUAL BRAKE BLEEDING
Bleed new or overhauled master cylinder on
bench before installation. This shortens overall
bleed time and ensures proper cylinder operation.
Refer to procedure in Master Cylinder Service sec
tion.
Bleed master cylinder first, combination valve sec
ond, rear antilock valve third and front antilock
valve fourth. Bleed cylinder and valves at brakeline
fittings one at a time. Procedure is as follows:
(1) Remove cap or caps and fill reservoir with
fresh Mopar, or equivalent quality brake fluid.
(2) Loosen brakeline fitting about 1-1/2 turns.
(3) Have helper press and, h o l d brake pedal to
floor. Observe condition of fluid coming out of brake-
line fitting.
(4) Tighten brakeline fitting and have helper
release brake pedal. Be sure to t i g h t e n f i t t i n g
before helper releases brake pedal.
(5) Continue bleeding until fluid coming out of fit
ting, is clear and free of bubbles.
NEW FRONT ANT1L0C1 WALWE

If a new front antilock valve assembly was
installed, bleed new valve as follows:
(1) Loosen bleed plug on new front valve about 1/4 Fig. 3 Front Antilock Valve Bleed Valve Stem & Plug
to one full turn (Fig. 3). Plug must be open to fully ORIGINAL FRONT ANT1L0CI WALWE
bleed upper and lower sections of front antilock If original assembly is being used, bleed plug and
valve. bleed valve do not have to be open during bleeding
(2) Remove cap from bleed valve stem (Fig. 3). operations. Just bleed the valve assembly at each
(3) Install Valve Depressor Tool 6670 on bleed brakeline fitting one at a time
valve stem by sliding notched side of tool onto boss Bleed first wheel brake unit. Start at left rear
that surrounds bleed valve stem (Fig. 4). wheel and follow sequence recommended. Repeat
(4) Tighten thumbscrew on bleed Tool 6670 just bleeding operation at each wheel until fluid coming
enough to push valve stem inward about 0.51 - 0.76 out of bleed screw is clear and free of bubbles.
mm (0.020 - 0.030 in.). Stem must be held inward (in Top off master cylinder reservoir fluid level. Then
open position) to fully bleed upper section of new verify proper brake operation before moving vehicle.
valve assembly.
(5) Apply brake pedal. Pedal will fall off signifi
cantly when bleed plug is properly open and bleed
SERVICE PH©€EPUHES (Continued)
SPECIAL TOOL GROUND.
6670
PRESSURE
DIFFERENTIAL
SWITCH
WIRE
RWAL
VALVE
HARNESS
AND
J9305-70: CONNECTOR J9405-77
Fig. 4 Front Antilock Valve Bleed Tool Fig, 5 Waive Harness

Vacuum Bleeding
i f vacuum bleeding equipment is being used, i t is
not necessary to hold the front brake metering valve
open. Simply bleed the brakes following the bleed
equipment manufacturers instructions.
Pressure Bleeding
If pressure bleeding equipment will be used, the
front brake metering valve will have to be held open
to bleed the front brakes. The valve stem is located
in the forward end of the combination valve. The
stem must either be pressed inward, or held outward
slightly, a spring clip tool or helper is needed to hold
the valve stem in position. COMBINATION
VALVE
Follow the manufacturers instructions carefully
when using pressure equipment. Do not exceed the
RWAL VALVE
tank manufacturers pressure recommendations. Gen
erally, a tank pressure of 15-20 psi is more than suf
ficient for bleeding purposes. LINE
TO
Fill the bleeder tank with recommended fluid and FRONT
purge air from the tank lines before bleeding. BRAKES J9405-82
Do pressure bleed without a proper master cylin
der adapter. The wrong adapter can lead to leakage, Fig. 6 Master Cylinder brake lines
or drawing air back into the system.
Make sure the front brake metering valve in the (4) Remove nuts attaching master cylinder and
combination valve is held open. A spring clip tool is combination valve bracket to booster studs.
best for securing the valve stem in an open position. (5) Remove master cylinder.
(6) Remove combination valve, valve bracket and
RWAL valve as assembly.
1E1 (7) Remove brake line connecting combination
valve to RWAL valve.
RWAL VALVE/COMBINATION VALVE (8) Remove bolt attaching RWAL valve to combina
tion valve bracket (Fig. 7). Then separate RWAL
REMOVAL valve from bracket.
(1) Disconnect ground wire and harness wires from
combination valve switch and RWAL valve (Fig. 5). INSTALLATION '
(2) Disconnect lines to front and rear brakes from (1) Install RWAL valve on combination valve
RWAL and combination valves (Fig. 6). bracket. Do not tighten RWAL valve bolt completely
(8) Remove brake lines connecting master cylinder at this time.
to combination valve.
Fig. 7 RWAL Valve/Combination Valve Fig. 8 CAB Harness Connector
(2) Install short brake line that connects RWAL (4) Install negative battery cable.
valve to combination valve. Tighten line fittings to
16-23 N-m (140-200 in. lbs.). HYDRAULIC CONTROL UNIT/CONTROLLER
(3) Tighten RWAL valve attaching bolt to 23-34 ANITL0CK BRAKE
N-m (200-300 in. lbs.).
(4) Install master cylinder on booster mounting REMOVAL
studs. (1) Disconnect ABS harness at HCU (Fig. 9).
(5) Attach antilock harness ground wire to combi (2) Unlatch and disconnect harness at controller.
nation valve bracket.
(6) Install combination valve bracket on booster
mounting studs and against master cylinder.
(7) Loosely install nuts that retain master cylinder
and combination valve on booster studs.
(8) Install and connect all remaining brake lines.
Tighten line fittings to 16-23 N-m (140-200 in. lbs.).
(9) Connect harness wires to RWAL valve and to
combination valve switch.
CONTROLLER ANTILOCK BRAKE (CAB) .
REMOVAL
(1) Remove and isolate negative battery cable.
(2) Release CAB connector locking handle and
remove connector (Fig. 8). Fig. 9 ABS Harness
(3) Remove the 2 CAB mounting bolts and remove
CAB from bracket. (3) Disconnect lines to front brakes at HCU (Fig.
10).
INSTALLATION (4) Remove stud nuts and bolt that attach HCU to
(1) Install CAB in mounting bracket. inner fender panel (Fig. 11). Then remove valve from
(2) Install mounting bolts. engine compartment.
(3) Connect harness and lock into place with lock
ing handle.
5 - 76 BRAKES BR
REMOVAL AND ITALLATION (Continued)
ABS VALVE FRONT SPEED SENSOR

FRONT AIS
BRAKELINES MODULE
REMOVAL
(1) Raise vehicle and support vehicle front end.
(3) Press caliper piston back into bore with pry
tool.
(4) Remove brake caliper bolts and lift caliper from
knuckle and rotor. Secure caliper to frame or chassis
component with wire. Do not allow brake hose to
support caliper weight.
(5) Remove rotor, refer to Group 5 Brakes.
(6) Remove bolts attaching sensor to steering
knuckle (Fig. 12). Retain bolts. They are special and
J9405-98 must be reused i f in good condition.
(7) Disconnect sensor wire and remove sensor from
Fig. 10 HCU Brakelines vehicle.
ABS VALVE
AND MODULE
ASSEMBLY
SENSOR
INNER BOLTS (2)
FENDER
PANEL
STEERING
STUD KNUCKLE
SPLASH
PLATE FRONT
SHIELD
(ON UNDERBODY) J9405-99 SENSOR J9505-1U
Fig. 11 HCU Mounting Fig. 12 Front Speed Sensor Mounting (2-Wheel

Drive Shown)
(5) I f valve is only being removed for access to
another component, cover brake line fluid ports with INSTALLATION
tape or plugs to prevent dirt entry. (1) Position sensor in knuckle.
(6) Remove bolts attaching CAB to HCU and (2) Install and tighten sensor bolts to 21-25 N-m
remove controller. (190-250 in. lbs.). Use original or replacement
sensor bolts only. The bolts are special and
INSTALLATION must not be substituted.
(1) Install module on HCU. (3) Connect sensor wire to harness wire from CAB.
(2) Position HCU on mounting studs. (4) Install rotor and brake caliper.
(3) Install and tighten mounting bolt and stud (5) Install wheel and tire assembly.
nuts. Tighten bolts and nuts to 10-13 N-m (92-112 in. (6) Lower vehicle.
lbs.). (7) Verify sensor operation with scan tool.
(4) Connect ABS harnesses to HCU and CAB. Be
sure CAB harness is securely latched in place. FRONT WHEEL SPEED SENSOR (4WD)
(5) Connect brake lines to HCU and tighten line
fittings to 19-23 N-m (170-200 in. lbs.). REMOVAL
(6) Fill and bleed brake system. (1) Remove bolt attaching sensor to the inside of
the steering knuckle.
(2) I n engine compartment, disconnect sensor wire
connector at harness plug.
(3) Remove sensor and wire assembly.
BR BRAKES 5 - 77
INSTALLATION
(1) Position sensor on steering knuckle. Seat sen
sor locating tab in hole in knuckle and install sensor
attaching bolt and tighten to 14 N-m (11 ft. lbs.).
(2) Route sensor wire from steering knuckle to
harness connector.
(3) Check sensor wire routing. Be sure wire is
clear of all chassis components and is not twisted or
kinked at any spot.
(4) Connect sensor wire to harness i n engine com
partment.
FRONT TONE WHEEL

The tone wheel for the front speed sensor is located
in the rotor hub on 2-wheel drive models (Fig. 13).
On 4-wheel drive models, the tone wheel is located
on the axle outer stub shaft.
The tone wheel is not a serviceable component. On
2-wheel drive models, the complete rotor and hub
assembly will have to be replaced i f the tone wheel is
damaged. On 4-wheel drive models, the driveshaft
will have to be removed and the axle outer stub shaft
replaced, i f the tone wheel is damaged.
Fig. 14 Rear Wheel Speed Sensor Mounting

(2) Position cover over sensor and install cover and
sensor attaching screw and tighten to 24 N-m (18 ft.
lbs.).
(3) Connect harness wires to sensor and lower
vehicle.
(4) Lower vehicle.
EXCITER RING
The exciter ring is mounted on the differential
case. I f the ring is damaged refer to Group 3 Differ
Fig. 13 Front Tone Wheel 2WD ential and Driveline for service procedures.
REAR WHEEL SPEED SENSOR
SPECIFICATIONS
REMOVAL
(1) Raise vehicle on hoist. TORQUE CHART
(2) Clean sensor, cover and sensor mounting area
of axle housing (Fig. 14). DESCRIPTION TORQUE
(3) Disconnect harness wires from sensor (Fig. 14). Hydraulic Control Unit
(4) Remove screw that secures brake cable, brake Mounting Bolts/Nuts . . .10-13 N-m (92-112 in. lbs.)
line, sensor cover and sensor in axle housing. Brake Lines. . . . . . . . .19-23 N-m (170-200 in. lbs.)
(5) Remove sensor and cover. RWAL Valve
(6) Cover sensor opening in axle housing to pre Mounting B o l t . . . 23-34 N-m (200-300 in. lbs.)
vent dirt entry. Brake Lines. . . . . 16-23 N-m (140-200 in. lbs.)
Wheel Speed Sensor
INSTALLATION
(1) Insert sensor in axle housing opening. Front Mounting Bolts .21-25 N-m (190-250 in. lbs.)
Rear Mounting Bolt . .24 N-m (212 in. lbs.)
5 - 78 BRAKES
SPECIAL TOOLS
ABS BRAKES
Depressor Brake Valve 6670

BR CLUTCH 6-1
CLUTCH
CONTENTS
page page
GENERAL INFORMATION GENERAL DIAGNOSIS INFORMATION 4 L-^.

CLUTCH COMPONENT LUBRICATION 3 INSPECTION AND DIAGNOSIS CHARTS 5
CLUTCH COMPONENTS 1 SERVICE PROCEDURES
CLUTCH COVER APPLICATION 2 CLUTCH LINKAGE 13
CLUTCH DISC APPLICATION 1 FLYWHEEL SERVICE 15
CLUTCH HYDRAULIC LINKAGE 3 REMOVAL AND INSTALLATION
CLUTCH LINKAGE FLUID 3 CLUTCH COVER AND DISC 15
CLUTCH PEDAL POSITION SWITCH 3 CLUTCH HOUSING REPLACEMENT—NV4500 . 18
INSTALLATION METHODS AND PARTS CLUTCH PEDAL 20
USAGE 4 PILOT BEARING 20
DIAGNOSIS AND TESTING RELEASE BEARING 19
NV4500 CLUTCH HOUSING 11 SPECIFICATIONS
CLUTCH PROBLEM CAUSES 4 TORQUE 21
G E N E R A L INFORMATION CLUTCH DISC APPLICATION

Two clutch disc diameters and four different thick
CLUTCH COMPONENTS nesses are used.
The clutch mechanism in BR models with a gas or A 281 mm (11 in.) diameter clutch disc is used with
diesel engine consists of a single, dry-type clutch disc a 3.9L, 5.2L, or 5.9L gas engines (Fig. 1) and (Fig. 2).
and a diaphragm style clutch cover. A hydraulic link
FACING
age is used to engage/disengage the clutch disc and MATERIAL
cover.
The transmission input shaft is supported in the
crankshaft by a bearing. A sleeve type release bear
ing is used to engage and disengage the clutch cover
pressure plate.
The release bearing is operated by a release fork in
the clutch housing. The fork pivots on a ball stud
mounted inside the housing. The release fork is actu
ated by a hydraulic slave cylinder mounted in the
housing. The slave cylinder is operated by a clutch
master cylinder mounted on the dash panel. The cyl
inder push rod is connected to the clutch pedal.
The clutch disc has damper springs i n the disc
hub. The clutch disc facing is riveted to the hub. The
facing is made from a non-asbestos material. The
clutch cover pressure plate is a diaphragm type with
a one-piece spring and multiple release fingers. The
pressure plate release fingers are preset during man
ufacture and are not adjustable.
Fig. 1 Clutch Disc—¥6 Engine

6 -2 CLUTCH BR
FACING FACING
MATERIAL MATERIAL
Ml 1DIESEL 1 J9406-10
J9406-8
Fig. 4 Clutch Disc—Diesel Engine

Fig. 2 Clutch Disc—V8 Engine
All the discs have damper springs in the hub. The
A 312.5 mm (12.3 in.) diameter clutch disc is used
281 mm discs have four springs while the 312.5 mm
with diesel and V10 engines (Fig. 3) and (Fig. 4).
disc has five springs. The damper springs provide
DAMPER
smoother torque transfer and disc engagement.
SPRINGS (5)
CLUTCH COWEFt APPOCAT10I
Two clutch covers are used for all applications. The
281 mm cover (Fig. 5), is used for 3.9L, 5.2L and 5.9L
gas engine applications.
COVER
1VIOl J9406-9
Fig. 3 Clutch Disc—¥10 Engine
281 mm
(11 m.) \V6N8] J9406-12
Fig. 5 Clutch Cover—¥6/¥8 Gas Engine

BR CLUTCH 6 -3

The 312.5 mm cover (Fig. 6), is used for 5.9L diesel DASH
and V10 gas engine applications. OPENING
COVER
RESERVOIR
DASH
PANEL
FLUID CYLINDER
LINES DASH SEAL
CLUTCH
MASTER
CYLINDER
SLAVE BODY
CYLINDER CLIP J9406-15
312.5 mm
(12.3 in.)
DIESEL/V10I J9406-11
Fig. 8 Clutch Hydraulic Linkage
The clutch master cylinder is connected to the
Fig. 6 Clutch Cower—¥10 and Diesel Engine clutch * pedal and the slave cylinder is connected to
CLUTCH PEDAL POSITION SWITCH the clutch release fork. The master cylinder is
mounted on the drivers' side of the dash panel adja
All BR models are equipped with a clutch pedal
cent to the brake master cylinder.
position switch (Fig. 7). The switch is in circuit with
the starter relay and is mounted on the clutch mas
CLUTCH LINKAGE FLUID
ter cylinder push rod. The switch is actuated by
The clutch' fluid reservoir, master cylinder, slave
clutch pedal movement. The clutch pedal must be
cylinder and fluid lines are prefilled with fluid at the
fully depressed in order to start the engine.
factory during assembly operations.
CLUTCH
The hydraulic system should not require additional
CLUTCH PEDAL
MASTER POSITION SWITCH fluid under normal circumstances. I n fact, the reser
CYLINDER voir fluid level will actually increase as normal
clutch wear occurs. For this reason, i t is important to
avoid overfilling, or removing fluid from the reser
voir. .
If inspection or diagnosis indicates additional fluid
may be needed, use Mopar brake fluid, or an equiv
alent meeting SAE and DOT standards J1703 and
J9506-26 DOT 3. Do not use any other type of fluid.
Fig. 7 Clutch Pedal Position (Interlock) Switch CLUTCH COMPONENT LUBRICATION

Proper clutch component lubrication is important
The position switch is an integral part of the clutch
to satisfactory operation. The correct lubricant and
master cylinder push rod and is not serviced sepa
not over lubricating are equally important. Apply rec
rately.
ommended lubricant sparingly to avoid disc and pres
Refer to Group 8W, Wiring Diagrams for compo
sure plate contamination.
nent locations and circuit information.
Clutch and transmission components requiring
lubrication are:
CLUTCH HYDRAULIC LINKAGE
• pilot bearing
The hydraulic linkage consists of a remote reser
• release lever pivot ball stud
voir, clutch master cylinder, clutch slave cylinder and
• release lever contact surfaces
interconnecting fluid lines (Fig. 8).
• clutch disc hub splines
I •4 CLUTCH
mm
• clutch pedal pivot shaft bore CLUTCH PROBLEM CAUSES
• clutch pedal bushings
• input shaft splines CONTAMINATION
• input shaft pilot hub Fluid contamination is one of the more common
• transmission front bearing retainer slide surface causes of clutch malfunctions. Oil, water, or clutch
Do not apply grease to any part of the clutch fluid on the clutch contact surfaces will result in
cover, disc, or release bearing. faulty operation. The usual result is chatter, slip, or
grab.
RECOMMENDED LUBRICANTS During inspection, note i f any components are con
Use Mopar multi-purpose grease for the clutch taminated with oil, hydraulic fluid, or water/road
pedal bushings and pivot shaft. Use Mopar high tem splash.
perature grease (or equivalent) for all other lubrica Oil contamination indicates a leak at either the
tion requirements. Apply recommended amounts and rear main seal or transmission input shaft.
do not over lubricate. Oil leakage produces a residue of oil on the hous
ing interior and on the clutch cover and flywheel.
INSTALLATION METHODS AND PARTS USAGE Heat buildup caused by slippage between the cover,
Distortion of clutch components during installation disc and flywheel, can sometimes bake the oil residue
and the use of non-standard components are addi onto the components. The glaze-like residue ranges
tional causes of clutch malfunction. in color from amber to black.
Improper clutch cover bolt tightening can distort Road splash contamination means dirt and water
the cover. The usual result is clutch grab,' chatter are entering the clutch housing due to loose bolts,
and rapid wear. Tighten the cover bolts as described housing cracks, vent openings, or through the slave
in the Clutch Service section. cylinder opening. Driving through deep water pud
Improperly seated flywheels and clutch housings dles can force water/road splash into the housing
are other causes of clutch failure. Improper seating through such openings.
will produce misalignment and subsequent clutch An additional problem caused by water contamina
problems. tion and especially by steam cleaning, involves clutch
Tighten the clutch housing bolts to proper torque disc sticking and poor release.
before installing any struts. Also be sure the align Water and steam vapors can be absorbed by the
ment dowels are in place and seated in the block and clutch facing material. I f the vehicle sits idle for long
housing beforehand. periods after water contamination, the force exerted
The use of non-standard or low quality parts can by the pressure plate may cause the disc to bond
also lead to problems and wear. Use the recom itself to the flywheel or pressure plate.
mended factory quality parts to avoid comebacks. Frequently, the only remedy for the above condi
tion is component replacement. To avoid this prob
lem, a vehicle should be driven as soon as possible to
DIAGNOSIS A U B TESTING
heat and dry the clutch components.
Clutch fluid leaks are from a loose or damaged
GENERAL DIAGNOSIS INFORMATION
slave cylinder line or connection. However, clutch
Unless the cause of a clutch problem is obvious, a
fluid leaks will usually be noted and corrected before
road test and component inspection will be required
severe contamination occurs.
for accurate diagnosis.
A road test will help determine the type of fault CLUTCH MISALIGNMENT
while component inspection will identify the problem Clutch components must be in proper alignment
component. with the crankshaft and transmission input shaft.
During a road test, drive the vehicle at normal Misalignment caused by excessive runout or warpage
speeds. Shift the transmission through all gear of any clutch component will cause grab, chatter and
ranges and observe clutch action. improper clutch release.
If chatter, grab, slip, or improper release is experi
enced, remove and inspect the clutch components. FLYWHEEL RUNOUT
However, i f the problem is noise or hard shifting, fur Common causes of runout are heat warping,
ther diagnosis is needed. The transmission or improper machining, mounting the flywheel on a
another driveline component may actually be at dirty crankshaft flange, incorrect bolt tightening, or
fault. improper seating on the crankshaft flange shoulder.
Careful observation during a road test will help Very light scratches or surface roughness on - the
narrow the problem area. flywheel face can be cleaned up by scuff sanding with
B R M _ _ CLUTCH § -1

180 grit emery cloth. However, i f the surface is between the crankshaft and transmission input
warped or severely scored, replace the flywheel. shaft.
Do not machine the flywheel. The flywheel Misalignment can cause noise, incomplete clutch
face is manufactured w i t h a unique surface release and chatter. I t can also result in premature
contour. Machining w o u l d negate this feature wear of the pilot bearing, cover release fingers and
and could result i n unsatisfactory operation. clutch disc. In severe cases, misalignment can also
Clean the crankshaft flange before mounting the cause premature wear of the transmission input
flywheel. Dirt and grease on the flange surface may shaft and bearing.
cock the flywheel causing runout. Housing face misalignment is generally caused by
Use new bolts when remounting a flywheel and incorrect seating on the engine or transmission, loose
secure the bolts with Mopar Lock And Seal, or Loc- housing bolts, missing alignment dowels or housing
tite 242. Tighten flywheel bolts to specified torque damage. Infrequently, misalignment may also be
only. Overtightening could distort the flywheel hub caused by housing mounting surfaces that are not
causing runout. parallel.
If housing misalignment is suspected, the housing
CLUTCH COWER AMD DISC RUNOUT is probably not fully seated on either the engine,
Check the clutch disc before installation. Axial alignment dowels, or transmission front face. Since
(face) runout of a new disc should not exceed 0.5 mm the NV3500 clutch housing is an integral part of the
(0.020 in.). Measure runout about 6 mm (1/4 in.) from transmission front case, it will be necessary to
the outer edge of the disc facing. Obtain another disc remove the transmission and housing as an assembly
if runout is excessive. to check seating. Housing bore and face runout can
Check condition of the clutch before installation. A only be checked in the vehicle on models with a
warped cover or diaphragm spring will cause grab NV4500 transmission. The runout check procedure is
and incomplete release or engagement. described in detail in the Clutch Service section.
Be careful when handling the cover and disc.
Impact can distort the cover, diaphragm spring, INSPECTION AND DIAGNOSIS CHARTS
release fingers and the hub of the clutch disc. The clutch inspection chart (Fig. 9) outlines items
Use an alignment tool when positioning the disc on to be checked before and during clutch installation.
the flywheel. The tool prevents accidental misalign Use the chart as a check list to help avoid overlook
ment which could result in cover distortion and disc ing potential problem sources during service opera
damage. tions.
A frequent cause of clutch cover distortion (and The diagnosis charts describe common clutch prob
consequent misalignment) is improper bolt tighten lems, causes and correction. Fault conditions are
ing. To avoid warping the cover, tighten the bolts listed at the top of each chart. Conditions, causes and
alternately (in a diagonal pattern) and evenly (2-3 corrective action are outlined in the indicated col
threads at a time) to specified torque. umns.
The charts are provided as a convenient reference
CLUTCH HOUSING MISALIGNMENT AND when diagnosing faulty clutch operation.
RUNOUT
Clutch housing alignment is important to proper
operation. The housing bore maintains alignment
6 -6 CLUTCH — BR
9 Inspect release bearing slide surface of trans, front

bearing retainer. Surface should be smooth, free of
nicks, scores. Replace retainer if necessary.
Lubricate slide-surface before installing release
bearing.
10 Do not replace release bearing unless actually

faulty. Replace bearing only if seized, noisy, or
damaged.
11 Check clutch cover diaphragm' spring and release •

fingers. Replace cover if spring or fingers are bent,
warped, broken, cracked. Do not tamper with
factory spring setting as clutch problems will result.
12 Check condition of clutch cover. Replace clutch

cover if plate surface is deeply scored, warped,
worn, or cracked. Be sure cover is correct size and
properly aligned on disc and flywheel.
13 Inspect clutch housing. Be sure bolts are tight.

Replace housing if damaged.
14 Verify that housing alignment dowels are in position

before installing housing.
15 Clean engine block surface before installing clutch

housing. Dirt, grime can produce misalignment.
1 Check clutch housing bolts. Tighten if loose. Be sure 16 Make sure side of clutch disc marked "flywheel
housing is fully seated on engine block. side" is toward flywheel.
2 Check flywheel. Scuff sand face to remove glaze. 17 Check rear main seal if clutch disc and cover were
Clean surface with wax and grease remover. oil covered. Replace seal if necessary.
Replace flywheel if severely scored, worn or
cracked. Secure flywheel with new bolts (if 18 Check crankshaft flange (if flywheel is removed). Be
removed). Do not reuse old bolts. Use Mopar Lock sure flange is clean and flywheel bolt threads are in
N'Seal on bolts. good condition.
3 Tighten clutch cover bolts 2-3 threads at a time, 19 Check pilot bearing. Replace bearing if damaged.
alternately and evenly (in a star pattern) to Lube with Mopar high temp, bearing grease before
specified torque. Failure to do so could warp the installation.
cover.
20 .Check transmission input shaft. Disc must slide freely
4 Check release fork. Replace fork if bent or worn. on shaft splines. Lightly grease splines before
Make sure pivot and bearing contact surfaces are installation. Replace shaft if splines or pilot bearing
lubricated. hub are damaged.
5- Check release fork pivot (in housing). Be sure pivot 21 Check flywheel bolt torque. If bolts are loose,
is secure and ball end is lubricated. replace them. Use Mopar Lock N'Seal to secure new
bolts.
6 Transmission input shaft bearing will cause noise,
chatter, or improper release i f damaged. Check 22 Check clutch disc facing. Replace disc if facing is
condition before installing transmission. charred, scored, flaking off, or worn. Also check
runout of new disc. Runout should not exceed 0.5
7 'Check slave cylinder. Replace it if leaking. Be sure mm (0.02 in.).
cylinder is properly secured in housing and cylinder
piston is seated in release fork.
8 Check input shaft seal if clutch cover and disc were

J9506-2
oil covered. Replace seal if worn, or cut.
Fig. 9 Clutch Inspection Points

BR . . CLUTCH 6•7
CLUTCH DIAGNOSIS
DISC FACING WORN OUT 1. Normal wear. Driver frequently 1. Replace clutch disc. Also replace cover
rides (slips) clutch. Results in rapid if spring is weak or pressure plate surface
wear overheating. Insufficient is damaged.
clutch cover diaphragm spring
tension.
CLUTCH DISC FACING 1. Leak at rear main seal or at 1. Replace leaking seals. Apply less grease
CONTAMINATED WITH transmission input shaft seal. to input shaft splines. Replace clutch disc
OIL, GREASE, OR Excessive amount of grease (do not clean and reuse). Clean clutch
CLUTCH FLUID applied to input shaft splines. cover and reuse only if cover is in good
Road splash, water entering condition. Replace slave cylinder if leaking.
housing. Slave cylinder leaking.
CLUTCH IS RUNNING 1. Release bearing sticking- 1. Verify that bearing is actually binding,
PARTIALLY DISENGAGED binding. Does not return to then replace bearing and transmission
normal running position. front bearing retainer if sleeve surface is
damaged.
FLYWHEEL HEIGHT 1. Flywheel surface improperly 1. Replace flywheel.

INCORRECT machined. Too much stock
removed or surface is tapered.
WRONG DISC OR PRES 1. Incorrect parts order or model 1. Replace with correct parts. Compare
SURE PLATE INSTALLED number. old and new parts before installation.
CLUTCH DISC, COVER 1. Rough handling (impact) bent 1. Install new disc or cover as needed.
AND/OR DIAPHRAGM cover, spring, or disc. Incorrect Follow installation/tightening instructions.
SPRING, WARPED, bolt tightening sequence and
DISTORTED method caused warped cover.
FACING ON FLYWHEEL 1. Flywheel surface scored and 1. Reduce scores and nicks by sanding or
SIDE OF DISC TORN, nicked. surface grinding. Replace flywheel if
GOUGED, WORN scores-nicks are deeper than .002-.004
inch.
CLUTCH DISC FACING 1. Frequent operation under high 1. Scuff sand flywheel. Replace clutch
BURNT (CHARRED). FLY loads or hard acceleration cover and disc. Alert driver to problem
WHEEL AND COVER conditions. Driver frequently cause.
PRESSURE PLATE rides (slips) clutch. Results in
SURFACES HEAVILY rapid wear and overheating of
GLAZED disc and cover.
J9506-18
6 - 8 CLUTCH BR
CONTINUED
CLUTCH DISC WARPED 1. New disc not checked for axial 1. Replace disc. Be sure runout of new
. runout before installation. disc is less than .5 mm (.020 in.).
CLUTCH DISC BINDS ON 1. Clutch disc hub splines 1. Clean, smooth and lubricate disc and
INPUT SHAFT SPLINES damaged during installation. shaft splines. Replace disc and/or input
Input shaft splines rough, shaft if splines are severely damaged.
damaged. Corrosion, rust
* formations on splines of disc
and input shaft.
CLUTCH DISC RUSTED 1. Occurs in vehicles stored, 1. Remove clutch cover and disc. Sand
TO FLYWHEEL AND/OR or not driven for extended rusted surfaces clean with 180 grit paper.
PRESSURE PLATE periods of time. Also occurs Replace disc cover, and flywheel if
after steam cleaning if vehicle corrosion is severe.
is not used for extended period.
CLUTCH DISC FACING 1. Vacuum may form in pockets 1. Drill 1 /16 inch diameter hole through
STICKS TO FLYWHEEL over rivet heads in clutch disc. rivets and scuff sand disc facing with 180
Occurs as clutch cools down grit paper.
after use.
CLUTCH DISC TOO THICK 1. Wrong disc installed. 1. Replace disc.
PILOT BEARING SEIZED, 1. Bearing cocked during 1. Lubricate and install new bearing.
LOOSE, OR ROLLERS installation. Bearing defective. Check and correct any misalignment.
ARE WORN Bearing not lubricated. Clutch
misalignment.
CLUTCH WILL NOT 1. Low clutch fluid level. 1. Top off reservoir and check for
DISENGAGE PROPERLY leaks.
2. Clutch cover loose. 2. Tighten bolts.
3. Wrong clutch disc. 3. Install correct disc.
4. Disc bent, distorted during 4. Replace disc.
installation.
5. Clutch cover diaphragm spring 5. Replace cover.
bent or warped during
transmission installation.
6. Clutch disc installed backwards. 6. Remove and reinstall disc correctly.
Be sure disc side marked "to flywheel" is
actually toward flywheel.
7. Release fork bent or fork pivot 7. Replace fork and pivot if worn or
is loose or damaged. damaged.
8. Clutch master or slave cylinder 8. Replace master and slave cylinder as
fault. assembly.
J9506-1
BR CLUTCH 6 - 9
CONTINUED
CLUTCH DISC FACING 1. Oil leak at rear main or input 1. Correct leak and replace disc (do not
COVERED WITH OIL, shaft seal. clean and reuse the disc).
GREASE, OR CLUTCH 2. Too much grease applied to 2. Apply lighter grease coating to splines
FLUID splines or disc and input shaft. and replace disc (do not clean and reuse
the disc).
CLUTCH DISC AND/OR 1. Incorrect or substandard parts. 1. Replace disc and/or cover with correct
COVER WARPED, OR DISC parts.
FACINGS EXHIBIT
UNUSUAL WRONG TYPE
CLUTCH MASTER OR 1. Master or slave cylinder 1. Replace both cylinders as assembly

SLAVE CYLINDER PLUNGER components worn or corroded. (and reservoir).
DRAGGING-BINDING
NO FAULT FOUND WITH 1. Problem actually related to 1. Further diagnosis required. Check
CLUTCH COMPONENTS suspension or driveline engine/transmission mounts, propeller
component. shafts and U-joints, tires, suspension
attaching parts and other driveline
components as needed.
2. Engine related problem. 2. Check EFI and ignition systems.
PARTIAL ENGAGEMENT 1. Clutch pressure plate 1. Replace clutch cover and disc.
OF CLUTCH DISC (ONE position setting incorrect or
SIDE WORN-OPPOSITE modified.
SIDE GLAZED AND 2. Clutch cover, spring, or release 2. Replace clutch cover and disc.
LIGHTLY WORN) fingers bent, distorted (rough
handling, improper assembly).
3. Clutch disc damaged or 3. Replace disc.
distorted.
4. Clutch misalignment. 4. Check alignment and runout of flywheel,
disc, or cover and/or clutch housing.
Correct as necessary.
J9506-20
CONTINUED
CONDITION POSSIBLE CAUSE CORRECTION
Clutch components damaged 1. Incorrect or sub-standard 1. Replace with parts of correct type and
or worn out prematurely. clutch parts. quality.
Pilot bearing damaged. 1. Bearing cocked during 1. Replace bearing. Be sure it is properly
installation. Bearing not lubricated seated and lubricated before installing
prior to installation. Bearing defect. clutch.
2. Clutch misalignment. 2. Check and correct misalignment caused
by excessive runout of flywheel, disc,
cover or clutch housing. Replace input
shaft if bearing hub is damaged.
Loose components. 1. Attaching bolts loose at 1. Tighten bolts to specified torque.

flywheel, cover, or clutch housing. Replace any clutch bolts that are damaged
Components appear overheated. 1. Frequent high load, full 1. Replace parts as needed. Alert driver
Hub of disc cracked or torsion throttle operation. to condition causes.
damper springs are distorted
or broken.
Contact surface of release 1. Clutch cover incorrect, or 1. Replace clutch cover and bearing.
bearing damaged. release fingers are bent or
distorted causing damage.
2. Release bearing defect. 2. Replace bearing.
3. Release bearing misaligned. 3. Check'and correct runout of clutch
components. Check front bearing retainer
sleeve surface. Replace if damaged.
Release bearing is noisy. 1. Release bearing defect. 1. Replace bearing.
Clutch pedal squeak. 1. Pivot pin loose. Pedal bushings 1. Tighten pivot pin. Replace bushings if
worn out or cracked. worn or damaged. Lubricate pin and
bushings with silicone base lubricator
chassis grease.
J9506-21
BR CLUTCH 6 -11

NV4500 CLUTCH HOUSING (7) Rotate the crankshaft until the indicator
plunger is at the top center of the housing bore. Zero
CHECKING RUNOUT the indicator at this point.
Only the NV4500 clutch housing can be (8) Rotate the crankshaft and record the indicator
checked using the following bore and face readings at eight points (45° apart) around the bore
r u n o u t procedures. The NV3500 clutch housing (Fig. 10) and (Fig. 11). Repeat the measurement at
is an integral p a r t of the transmission front least twice for accuracy.
case and can only be checked off the vehicle. (9) Subtract each reading from the one 180° oppo
site to determine magnitude and direction of runout.
i E A S U l i l G CLUTCH HOUSili BORE FtOIOUI—1¥45I0 Refer to (Fig. 12) and following example.
OILY Bore runout example:
(1) Remove the clutch housing and strut. 0.000 - (-0.007) = 0.007 in.
(2) Remove the clutch cover and disc. +0.002 - (-0.010) = 0.012 in.
(3) Replace one of the flywheel bolts with an ' +0.004 - (-0.005) = 0.009 in.
appropriate size threaded rod that is 10 in. (25.4 cm) -0.001 - (+0.001) ±= -0.002 in. (= 0.002 inch)
long (Fig. 10). The rod will be used to mount the dial In the above example, the largest difference is
indicator. 0.012 in. and is called the total indicator reading
7/16 - 20 THREAD NUT (TIR). This means that the housing bore is offset
from the crankshaft centerline by 0.006 in. (which is
STUD OR THREADED ROD 1/2 of 0.012 in.).
On gas engines, the acceptable maximum TIR for
housing bore runout is 0.010 inch. I f measured TIR is
more than 0.010 in. (as in the example), bore runout
will have to be corrected with offset dowels. Offset
dowels are available in 0.007, 0.014 and 0.021 in.
sizes for this purpose (Fig. 12). Refer to Correcting
Housing Bore Runout for dowel installation.
J9006-25
.000
Fig. 10 Dial Indicator Mounting Stud Or Rod
002
(4) Remove the release fork from the clutch hous
ing.
(5) Reinstall the clutch housing. Tighten the hous
+ .004
ing bolts nearest the alignment dowels first.
(6) Mount the dial indicator on the. threaded rod
and position the indicator plunger on the surface of
the clutch housing bore (Fig. 11).
MOUNTING STUD DIAL INDICATOR
CLUTCH
HOUSING
BORE
(SAMPLE READINGS) J9006-27
CIRCLE
NDSCATOR
PLUNGER
Fig. 12 Housing Bore Measurement Points And
Sample Readings
On diesel engines, the acceptable maximum
T I R for housing bore runout is 0.015 inch. How
ever, unlike gas engines, offset dowels are not
available to correct runout on diesel engines. If
bore runout exceeds the stated maximum on a
CLUTCH diesel engine, it may be necessary to replace
HOUSING either the clutch housing, or transmission
BORE J9006-26
adapter plate.
Fig. 11 Checking Clutch Housing Bore Runout
6 -12 CLUTCH BR
Correcting Clutch Housing Bore Runout—NV4500 l a s INDICATOR DIAL INDICATOR
Engine Only PLUNGER CLUTCH
HOUSING
On gas engine vehicles, clutch housing bore runout FACE
is corrected with offset dowels. However, i f bore
runout exceeds 0 . 0 1 5 in. TIR on a diesel equipped
model, the clutch housing, or transmission adapter
plate may have to be replaced. Offset dowels are not
available for diesel models.
The dial indicator reads positive when the plunger
moves inward (toward indicator) and negative when
it moves outward (away from indicator). As a result,
the lowest or most negative reading determines the
direction of housing bore offset (runout).
In the sample readings shown (Fig. 1 3 ) and in Step
INDICATOR MOUNTING
7 above, the bore is offset toward the 0 . 0 1 0 inch STUD OR ROD J9006-29
reading. To correct this, remove the housing and orig
inal dowels. Then install the new offset dowels in the Fig. 14 Measuring Clutch Housing Face Runout
direction needed to center the bore with the crank
( 3 ) Measure and record face runout at four points
shaft centerline.
9 0 ° apart around the housing face (Fig. 1 5 ) . Perform
In the example, TIR was 0 . 0 1 2 inch. The dowels the measurement at least twice for accuracy.
needed for correction would have an offset of 0 . 0 0 7
in. (Fig. 1 3 ) .
SLOT S H O W S DIRECTION OFFSET

OF OFFSET DOWEL + .009
DOWEL SELECTION
mm OFFSET DOWEL CLUTCH .004
HOUSING
VALUE REQUIRED FACE (SAMPLE READINGS)
CIRCLE
0.011 - 0 . 0 2 1 inch 0 . 0 0 7 inch
(AT RIM
0 . 0 2 2 - 0 . 0 3 5 inch 0 . 0 1 4 inch O F BORE) J9006-30
0 . 0 3 6 - 0 . 0 5 2 inch 0.021 inch Fig. 15 Housing Face Measurement Points And

J9206-7 Sample Readings
Fig. 13 Housing Bore Alignment Dowel Selection ( 4 ) Subtract the lowest reading from the highest to
determine total runout. As an example, refer to the
Install the dowels with the slotted side facing out sample readings shown (Fig. 17). I f the low reading
so they can be turned with a screwdriver. Then was minus 0 . 0 0 4 in. and the highest reading was
install the housing, remount the dial indicator and plus 0 . 0 0 9 in., total runout is actually 0 . 0 1 3 inch.
check bore runout again. Rotate the dowels until the ( 5 ) Total allowable face runout is 0 . 0 1 0 inch. I f
TIR is less than 0 . 0 1 0 in. i f necessary. runout exceeds this figure, runout will have to be
I f a TIR of 0 . 0 5 3 in. or greater is encountered, i t corrected. Refer to Correcting Clutch Housing Face
may be necessary to replace the clutch housing. Runout.
Measuring Clutch Housing Face Runout—NV4500 CORRECTING CLUTCH HOUSING FACE
( 1 ) Reposition the dial indicator plunger on the RUNOUT—NV4500
housing face (Fig. 1 4 ) . Place the indicator plunger at Housing face runout, on gas or diesel engines, can
the rim of the housing bore as shown. be corrected by installing shims between the clutch
( 2 ) Rotate the crankshaft until the indicator housing and transmission (Fig. 16). The shims can be
plunger is at the 1 0 O'clock position on the bore. made from shim stock or similar materials of the
Then zero the dial indicator. required thickness.
As an example, assume that face runout is the
same as shown i n (Fig. 1 7 ) and in Step 4 . I n this
CUT/DRILL
BOLT
HOLE
TO SIZE .000 + .009
SHIM
STOCK
CLUTCH -.003yf .004

HOUSING
FACE (SAMPLE READINGS)
CIRCLE
MAKE SHIM (AT RIM
1-INCH OF BORE) J9006-30
DIAMETER J9006-31
Fig. 18 Housing Face Measurement Points And
Fig. 16 Housing Face Alignment Shims Sample Readings
case, three shims will be needed. Shim thicknesses b e serviced separately. The linkage cylinders
should be 0.009 in. (at the 0.000 corner), 0.012 in. (at and connecting lines are sealed units. They are
the -0.003 corner) and 0.013 in. (at the -0.004 cor pre-filled with fluid during manufacture and
ner). must not be disassembled nor disconnected.
After installing the clutch assembly and housing,
tighten the housing bolts nearest the alignment dow Linkage Removal
els first. (1) Raise vehicle.
Clutch housing preferred bolt torques are: (2) On diesel models, remove slave cylinder shield
• 41 N-m (30 ft. lbs.) for 3/8 in. diameter bolts from clutch housing i f equipped.
• 68 N-m (50 ft. lbs.) for 7/16 in. diameter bolts (3) Remove nuts attaching slave cylinder to studs
• 47 N-m (35 ft. lbs.) for V10 and diesel clutch on clutch housing.
housing bolts (4) Remove slave cylinder from clutch housing.
During final transmission installation, install the (5) Disengage slave cylinder fluid line from body
shims between the clutch housing and transmission retainer clips.
at the appropriate bolt locations. (6) Lower vehicle.
(7) Disconnect clutch pedal interlock switch wires.
INDICATOR DIAL INDICATOR
PLUNGER CLUTCH (8) Remove locating clip from clutch master cylin
HOUSING der mounting bracket (Fig. 19).
FACE
(9) Remove retaining clip, flat washer and wave
washer that attach clutch master cylinder push rod
to clutch pedal (Fig. 20).
(10) Slide clutch master cylinder push rod off
pedal pin.
(11) Inspect condition of bushing on clutch pedal
pin (Fig. 20). Remove and replace bushing i f worn or
damaged.
(12) Verify that cap on clutch master cylinder res
ervoir is tight. This will avoid spillage during
removal.
INDICATOR MOUNTING
J9006-29
(13) Remove screws that attach clutch fluid reser
STUD OR ROD
voir to dash panel.
Fig. 17 Measuring Clutch Housing Face Runout (14) Remove reservoir mounting bracket screws
and remove reservoir from dash panel.
SERVICE PROCEDURES (15) Rotate clutch master cylinder 45° counter
clockwise to unlock it. Then remove cylinder from
CLUTCH LINKAGE dash panel.
The clutch master cylinder, remote reservoir, (16) Remove clutch master cylinder rubber seal
slave cylinder and connecting lines are all ser from dash panel (Fig. 19).
viced as an assembly. These components cannot
6 - 14 CLUTCH BR
SERVICE PROCEDURES {Continued)

CYLINDER
RESERVOIR
LOCATING
PIN CLUTCH
& PUSH
. ^ - ^ ROD
CLUTCH
MASTER
CYLINDER
SLAVE
CYLINDER J9506-25
Fig. 19 Clutch Hydraulic Linkage

PIN (3) Lubricate cylinder seal with liquid dish soap to
ease installation. Then seat seal in dash and around
cylinder.
(4) Insert clutch master cylinder in dash panel.
Rotate cylinder 45° clockwise to lock i t in place.
(5) I f cylinder seal is hard to seat, unlock cylinder
and reseat seal i f necessary. Then lock cylinder after
ward.
(6) Position clutch fluid reservoir on dash panel
and install reservoir screws. Tighten screws to 5 N-m
(40 in. lbs.) torque.
(7) Install reservoir mounting bracket on dash
panel, i f removed.
(8) Install replacement bushing on clutch pedal pin
if necessary.
(9) Install clutch master cylinder push rod on
CLIP clutch pedal pin. Secure rod with wave washer, flat
washer and retainer ring.
(10) Connect clutch pedal position (interlock)
PEDAL switch wires.
J9406-21 (11) Install locating clip i n clutch master cylinder
mounting bracket.
Fig. 20 Clutch Cylinder Push Rod Attachment (12) Raise vehicle.
(13) Install slave cylinder. Be sure cap at end of
(17) Remove clutch cylinders, reservoir and con cylinder rod is seated i n release lever. Check this
necting lines from vehicle. before installing cylinder attaching nuts.
LINKAGE INSTALLATION
(14) Install and tighten slave cylinder attaching
(1) Tighten cap on clutch fluid reservoir to avoid nuts to 23 N-m (200 in. lbs.) torque.
spillage during installation. (15) Lower vehicle.
(2) Position cylinders, connecting lines and reser (16) I f new linkage has been installed, remove
voir in vehicle engine compartment. plastic shipping stop from master cylinder push rod.
Do this after installing slave cylinder and before
operating linkage.
CLUTCH 6 -15
S E R V I C E P R O C E D U R E S (Continued!
(17) Operate linkage several times to verify proper wheel. Then complete removal with a cold chisel or
operation. punch.
(4) The ring gear Is a shrink fit on the flywheel.
FLYWHEEL SERVICE This means the gear must be expanded by heating in
Inspect the flywheel whenever the clutch disc, order to install It. The method of heating and
cover and housing are removed for service. Check expanding the gear is extremely i m p o r t a n t .
condition of the flywheel face, hub, ring gear teeth, Every surface of the gear must be heated at the same
and flywheel bolts. time to produce uniform expansion. An oven or simi
Minor scratches, burrs, or glazing on the flywheel lar enclosed heating device must be used. Tempera
face can be scuff sanded with 180 grit emery cloth. ture required for uniform expansion is 325-350° F.
However, the flywheel should be replaced i f the disc
contact surface is severely scored, heat checked, CAUTION: Never use an oxy/acetylene torch to
cracked, or obviously worn. remove the old gear, or to heat and expand a new
Cleanup of minor flywheel scoring should be per gear. The high temperature of the torch flame will
formed with surface grinding equipment. Remove cause localized heating and damage the flywheel. In
only enough material to reduce scoring (approximate addition, using the torch to heat a replacement gear
ly 0.001 - 0.003 in.). Heavy stock removal is not rec will cause uneven heating and expansion. The torch
ommended. Replace the flywheel If scoring Is severe flame will also anneal the gear teeth resulting in
and deeper than 0.076 mm (0.003 in.). Excessive rapid wear and damage after installation.
stock removal can result in flywheel cracking or
warping after Installation; It can also weaken the fly (5) The heated gear must be installed evenly to
wheel and Interfere with proper clutch release. avoid misalignment or distortion. A shop press and
Check flywheel runout i f misalignment Is sus suitable press plates should be used to install the
pected. Runout should not exceed 0.08 mm (0.003 gear i f at all possible.
in.). Measure runout at the outer edge of the fly (6) Be sure to wear eye and hand protection. Heat
wheel face with a dial Indicator. Mount the dial indi resistent gloves and safety goggles are needed for
cator on a stud installed in place of one of the personal safety. Also use metal tongs, vise grips, or
flywheel attaching bolts. similar tools to position the gear as necessary for
Clean the crankshaft flange before mounting the installation.
flywheel. Dirt and grease on the flange surface may (7) Allow the flywheel and ring gear to cool down
cock the flywheel causing excessive runout. before installation. Set the assembly on a workbench
Check condition of the flywheel hub and attaching and let i t cool i n normal shop air.
bolts. Replace the flywheel i f the hub exhibits cracks
CAUTION: Never use water, or compressed air to
In the area of the attaching bolt holes.
cool the flywheel. The rapid cooling produced by
Install new attaching bolts whenever the flywheel
water or compressed air can distort, or crack the
is replaced and use Mopar Lock N ' Seal, or Loctite
gear and flywheel.
242 on replacement bolt threads.
Recommended flywheel bolt torques are:
• 75 N-m (55 ft. lbs.) for gas engine flywheels
• 137 N-m (101 ft. lbs.) for diesel flywheels REMOVAL AND INSTALLATION
inspect the teeth on the starter ring gear, i f the
teeth are w o r n or damaged, the flywheel should CLUTCH COVER AND DISC
be replaced as an assembly. This is the recom
mended and preferred method of repair. REMOVAL
In cases where a new flywheel is not readily avail (1) Raise vehicle.
able, a replacement ring gear can be installed. How (2) Remove transmission and transfer case i f
ever, the following precautions must be observed to equipped. Refer to Group 21 for procedures.
avoid damaging the flywheel and replacement gear. (3) On models with NV4500 transmission, remove
(1) Mark position of the old gear for alignment ref clutch slave cylinder from clutch housing (Fig. 21).
erence on the flywheel. Use a scriber for this pur Then remove transmission and clutch housing from
pose. engine (Fig. 22).
(2) Wear protective goggles or approved safety (4) Support engine with wood block and adjustable
glasses. Also wear heat resistant gloves when han jack stand (Fig. 23). Supporting engine is necessary
dling a heated ring gear. to avoid undue strain on engine mounts.
' (3) Remove the old gear by cutting most of the way (5) I f clutch cover will be reused, mark position of
through i t (at one point) with an abrasive cut-off cover on flywheel with paint or scriber (Fig. 24).
6 - 16 CLUTCH
R E M O V A L AHP I N S T A L L A T I O N fConflnued)
MOUNTING ALIGNMENT
STUDS MARKS
19-26 N-m FLYWHEEL (SCRIBE OR PAINT)
(170-230 in. lbs.)
FLUID
LINE
CLUTCH
HOUSING
SLAVE
CYLINDER J9406-13
Fig, 21 Siave Cylinder Mounting
CLUTCH
HOUSING
CLUTCH
COVER J9406-17
Fig. 24 Marking Clutch Cover Position

NV4500
TRANSMISSION (7) I f clutch cover will be reused, loosen cover bolts
/ evenly, only few threads at a time, and in a diagonal
pattern (Fig. 25). This relieves cover spring tension
evenly to avoid warping.
J9406-16
Fig, 22 Transmission/Clutch Housing—NV4500
J9106-17
J9106-22 Fig. 25 Clutch Cover Bolt Loosening/Tightening

Pattern
Fig. 23 Supporting Engine With Jack Stand And
Wood Block—Diesel Model Shown (8) Remove cover bolts completely and remove
cover, disc and alignment tool.
(6) Insert clutch alignment tool in clutch disc and
into pilot bushing. Tool will hold disc in place when
cover bolts are removed.
CLUTCH COVER AND DISC INSTALLATION (7) Align and hold clutch cover in position and
(1) Check runout and free operation of new clutch Install cover bolts finger tight.
disc: (8) Tighten cover bolts evenly and a few threads at
(a) Install disc on transmission Input shaft a time. Cover bolts must be tightened evenly
splines and check fit. Disc should slide freely on and to specified torque to avoid distorting
splines. cover.
(b) Leave disc on shaft and check disc runout • Tighten 5/16 in. diameter bolts to 23 N-m (17 ft.
with dial indicator. lbs.)
(c) Position indicator plunger about 1/4 inch • Tighten 3/8 in. diameter bolts to 41 N-m (30 ft.
from outer edge of disc facing. lbs.).
(d) Runout should not exceed 0.5 mm (0.020 In.). (9) Remove release lever and release bearing from
Obtain another clutch disc If runout exceeds this clutch housing. Apply Mopar high temperature bear
limit. ing grease to bore of release bearing, release lever
(2) Lubricate crankshaft pilot bearing with Mopar contact surfaces and release lever pivot stud (Fig.
high temperature bearing grease. 28).
(3) Insert clutch alignment tool In clutch disc hub.
(4) Verify that disc hub is positioned correctly. Side
of hub marked Flywheel Side should face flywheel
(Fig. 26).
Fig. 26 dutch Disc Position (Typical)

(5) Insert alignment tool in pilot bearing and posi
tion disc on flywheel surface (Fig. 27).
Fig. 28 Clutch Release Component Lubrication

Points
(10) Apply light coat of Mopar high temperature
bearing grease to splines of transmission input shaft
(or drive gear) and to release bearing slide surface of
Fig. 27 Clutch Disc And Cower Alignment/ . the transmission front bearing retainer (Fig. 29). Do
Installation not over lubricate shaft splines. This can result
in grease contamination of disc.
(6) Position clutch cover over disc and onto fly
wheel (Fig. 27). (11) Install release lever and bearing i n clutch
housing. Be sure spring clips that retain fork on
6 - 18 CLUTCH mm
R E M O V A L AW© I N S T A L L A T I O N (Continued)
ENGINE BLOCK CLUTCH DISC A N D COVER
APPLY LIGHT COAT O F

HI-TEMP GREASE TO THESE
SURFACES BEFORE INSTALLATION • J9106-15
Fig. 29 input Shaft Lubrication Points—Typical

pivot ball and release bearing on fork are properly
installed and (Fig. 30).
FORK
J9O06-32
Fig. 31 Clutch Housing Installation—NV4500
J9406-18
Fig, 30 Release Fork And Bearing Spring Clip

Position
(12) Install clutch housing (Fig. 31) and (Fig. 32).
Be sure housing is properly seated on alignment
dowels before tightening housing bolts.
(13) Install transmission.
(14) Check fluid level in clutch master cylinder.
CLUTCH HOUSING REPLACEMENT—NV4500

Only the NV4500 clutch housing is serviced sepa
rately. The NV3500 clutch housing is part of the
transmission front case and is therefore serviced only
as part of the case assembly.
(1) Raise vehicle and remove transmission and
transfer case i f equipped.
(2) Remove clutch housing bolts and remove hous
Fig. 32 Clutch Housing/Transmission Installation—
ing from engine (Fig. 33) and (Fig. 34).
Diesel Engine
(3) Clean housing mounting surface of engine
block with wax and grease remover. (4) Verify that clutch housing alignment dowels
are in good condition and properly seated.
BR CLUTCH 6 - 19
/ /-a* CLUTCH els first and to torque values indicated (Fig. 33) and
f-^Vx HOUSING (Fig. 34).
(8) Install transmission-to-engine strut after
installing clutch housing. Tighten bolt attaching
strut to clutch housing first and engine bolt last.
NV4500 (9) Install transmission and transfer case i f
TRANSMISSION equipped. Refer to procedure in Group 21.
1
RELEASE BEARING '
REMOVAL
(1) Remove transmission.
(2) On models with gas engine and new style
release fork, remove clutch housing for access to
release fork and release bearing retainer springs.
J9406-16
(3) Disconnect release bearing from release fork
Fig. 33 Transmission/Clutch Housing—NV4500
and remove bearing (Fig. 35).
ENGINE BLOCK CLUTCH DISC A N D COVER
RELEASE BEARING RELEASE

AND SLEEVE FORK RN1232
Fig. 35 dutch Release Components

RELEASE BEARING INSTALLATION '
(1) Inspect bearing slide surface on transmission
front bearing retainer. Replace retainer i f slide sur
face is scored, worn or cracked.
(2) Inspect release lever and pivot stud. Be sure
stud is secure and in good condition. Be sure fork is
not distorted or worn. Replace fork spring clips i f
bent or damaged.
(3) Lubricate crankshaft pilot bearing, input shaft
splines, bearing retainer slide surface, lever pivot
J9006-32
ball stud and release lever pivot surface with Mopar
high temperature bearing grease.
Fig. 34 dutch Housing Installation—NV4500
(4) Install release fork and release bearing (Fig.
(5) Transfer slave cylinder, release fork and boot, 36). Be sure fork and bearing are properly secured by
fork pivot stud and wire/base brackets to new hous spring clips.
ing. (5) Install clutch housing, i f removed.
(6) Lubricate release, fork and pivot contact sur (6) Install transmission. Also install transfer case
faces with Mopar High Temperature wheel bearing on 4-wheel drive models.
grease before installation.
(7) Align and Install clutch housing on transmis
sion. Tighten housing bolts closest to alignment dow
i - 20 CLUTCH BR
BEARING SEAL
MUST FACE
Fig. 36 Clutch Release Fork And Bearing, Installation
PILOT BEARING
REMOVAL J9206-8
(1) Remove transmission and clutch housing.
(2) Remove clutch cover and disc. Fig. 37 Typical Method Of Installing Pilot Bearing
(3) Remove pilot bearing. Use blind hole puller PIN
tools such as those included in Snap-On set CG40CB
to remove bearing.
INSTALLATION
(1) Clean bearing bore with solvent and wipe dry
with shop towel.
(2) Install new bearing with clutch alignment tool
(Fig. 37). Keep bearing straight during installation.
Do not allow bearing to become cocked. Tap bearing
into place until flush with edge of bearing bore. Do
not recess bearing.
(3) Lubricate bearing with Mopar high tempera
ture grease, or an equivalent quality grease.
(4) Install clutch cover and disc.
(5) Install clutch housing, transmission and trans
fer case on 4-wheel drive models.
CLUTCH PEDAL
PEDAL
REMOVAL
J9406-21
(1) Remove retaining ring, flat washer and wave
washer that secure brake and clutch pedals to push
Fig. 38 Clutch Cylinder Push Rod Attachment
rods (Fig. 38).
(2) Remove knee bolster (Fig. 39) for access to necessary to remove shaft from pedal support
pedal pivot shaft. entirely.
(3) Remove brake light switch. Turn switch clock (6) Remove clutch pedal.
wise about 30° to release it then remove switch from
bracket. CLUTCH PEDAL INSTALLATION
(4) Remove retainer from passenger side of pedal (1) Inspect bushings in clutch and brake pedals
pivot shaft (Fig. 40). (Fig. 41). Replace bushings i f worn, cracked, or dis
(5) Push pedal pivot shaft toward driver side of torted.
support only enough to remove clutch pedal. I t is not
BR CLUTCH 8 - 21
Fig. 41 Clutch/Brake Pedal Bushings

Fig. 39 Knee Bolster Removal (3) Position clutch pedal in support. Align pedal
with pivot shaft and slide shaft through pedal bush
PEDAL PEDAL
SUPPORT PIVOT ings. Then repeat process for brake pedal.
(4) Slide pedal shaft through support and install
shaft retainer.
(5) Secure push rods to clutch and brake pedals.
(6) Install brake light switch In bracket. Rotate
switch into place to lock it in bracket.
SPECIFICATIONS
TORQUE
DESCEIPTION TORQUE
Nut, slave cylinder . 19-26 N-m (170-230 in. lbs.)
Bolt, clutch cover—5/16 in. . . . . . 23 N-m (17 ft. lbs.)
Bolt, clutch cover—3/8 i n . . . . . . . .41 N-m (30 ft. lbs.)
Pivot, release bearing . . . . . . . . . .23 N-m (17 ft. lbs.)
Bolt, housing to engine—
3/8 i n . . . . 45 N-m (33 ft. lbs.)
J9406-22
Bolt, housing to engine—
7/16 In. .68 N-m (50 ft. lbs.)
Fig. 40 dutch/Brake Pedal Mounting Bolt, housing to engine—V-10 . . . 47 N-m (35 ft. lbs.)
Screw, fluid reservoir .5 N-m (40 In. lbs.)
(2) Lubricate pedal shaft, pedal shaft bore (Fig. 40)
and (Fig. 41) and all bushings with Mopar Multi
Mileage, or high temperature bearing grease.
BR — - _ _ _ _ _ COOLING SYSTEM 7 - 1
COOLING SYSTEM
CONTENTS
page page
GENERAL INFORMATION RADIATOR COOLANT FLOW TEST 27

BELT TENSION—ALL ENGINES 5 SERPENTINE DRIVE BELT DIAGNOSIS—ALL
COOLANT RESERVE/OVERFLOW SYSTEM . . . . 3 ENGINES 29
COOLANT 3 TESTING COOLING SYSTEM FOR LEAKS . . . . 27
COOLING SYSTEM COMPONENTS AND THERMOSTAT—DIESEL ; 31
FLOW—DIESEL 3 THERMOSTAT—GAS ENGINES 31
COOLING SYSTEM COMPONENTS AND VISCOUS FAN DRIVE 28
FLOW—GAS ENGINES 2 WATER PUMP 31
COOLING SYSTEM 2 SERVICE PROCEDURES
ENGINE ACCESSORY DRIVE BELTS 5 ADDING ADDITIONAL COOLANT—ROUTINE . . 33
RADIATOR P R E S S U R E CAP 3 COOLANT LEVEL CHECK—ROUTINE 33
RADIATORS 4 COOLANT LEVEL C H E C K — S E R V I C E 33
THERMOSTAT 4 COOLANT S E R V I C E — D I E S E L ENGINE 33
DESCRIPTION AND OPERATION COOLANT S E R V I C E — V - 6 , V-8, AND V-10
AIR-TO-OIL COOLER 6 ENGINES 33
AUTOMATIC BELT TENSIONER 7 COOLING SYSTEM CLEANING/REVERSE
AUTOMATIC TRANSMISSION OIL COOLERS- FLUSHING 34
DIESEL ENGINE 7 DRAINING COOLING SYSTEM 33
AUTOMATIC TRANSMISSION OIL COOLERS- REFILLING COOLING S Y S T E M 34
GAS ENGINES 6 REMOVAL AND INSTALLATION
COOLANT PERFORMANCE 9 AIR-TO-OIL COOLER—3.9L/5.2L/5.9L ENGINES . 50
COOLANT RESERVE/OVERFLOW S Y S T E M . . . 11 AIR-TO-OIL C O O L E R — 5 . 9 L DIESEL ENGINE . 52
COOLANT SELECTION-ADDITIVES 10 AIR-TO-OIL C O O L E R — 8 . 0 L V-10 ENGINE . . . . 51
COOLING SYSTEM HOSES AND CLAMPS . . . . 11 AUTOMATIC BELT TENSIONER 57
ENGINE BLOCK HEATERS 9 COOLANT RESERVE/OVERFLOW TANK 35
RADIATOR P R E S S U R E CAP 10 COOLING SYSTEM FAN D R I V E — D I E S E L
THERMOSTAT—DIESEL 5 ENGINE 60
THERMOSTAT—V-6, V-8, AND V-10 5 COOLING S Y S T E M FAN—GAS ENGINES 59
VISCOUS FAN DRIVE 12 ENGINE BLOCK HEATER 54
WATER PUMPS—V-6, V-8, AND V-10 RADIATOR 53
ENGINES 11 REPLACING WATER-TO-OIL COOLER IN
WATER PUMP—5 9L DIESEL 11 RADIATOR SIDE TANK 50
DIAGNOSIS AND TESTING SERPENTINE DRIVE BELTS 55
COOLING SYSTEM DIAGNOSIS 15 THERMOSTAT—3.9L V-6 OR 5.2/5.9L V-8 . . . 46
DEAERATION 32 THERMOSTAT—8.0L V-10 47
DRB SCAN TOOL 14 THERMOSTAT—DIESEL ENGINE 48
LOW COOLANT LEVEL—AERATION 32 WATER PUMP BYPASS HOSE 42
ON-BOARD DIAGNOSTICS (OBD) 13 WATER PUMP—5.9L DIESEL 42
PRELIMINARY CHECKS 14 WATER PUMP—8.0L V-10 ENGINE 38
P R E S S U R E TESTING RADIATOR CAPS 32 WATER PUMP—V-6 AND V-8 ENGINES 35
RADIATOR CAP-TO-FILLER NECK S E A L - WATER-TO-OIL C O O L E R — 5 . 9 L DIESEL
P R E S S U R E RELIEF CHECK 32 ENGINE 5?
7 -2 COOLING SYSTEM BR
CLEANING A N i INSPECTION SPECIFICATIONS

FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 COOLANT CAPACITIES . . . . . . . . . . . . . . . . . . . 62
RADIATOR CAP 61 TORQUE . . . . 63
RADIATOR 61 SPECIAL TOOLS
WATER PUMP INSPECTION 61 COOLING 63
G E N E R A L INFORMATION COOLING SYSTEM COMPONENTS AND F L O W -

GAS ENGINES
COOLING SYSTEM The cooling system consists of:
The cooling system regulates engine operating tem • A cross-flow radiator
perature. I t allows the engine to reach normal oper • Thermal viscous fan drive
ating temperature as quickly as possible. I t also • Fan shroud
maintains normal operating temperature and pre • Radiator pressure cap
vents overheating. • Thermostat
The cooling system also provides a means of heat • Coolant reserve/overflow system
ing the passenger compartment and cooling the auto • Transmission oil cooler (automatic transmission)
matic transmission fluid (if equipped). The cooling • Coolant
system Is pressurized and uses a centrifugal water • Water pump (to circulate coolant)
pump on all engines to circulate coolant throughout • Hoses and hose clamps
the system. Typical coolant flow circuits for gas powered
An optional factory installed maximum duty cool engines are shown In (Fig. 1).
ing package Is available for some engines on most
models. This package will provide additional cooling
capacity for vehicles used under extreme conditions
such as trailer towing in high ambient temperatures.
BR COOLING SYSTEM 7-3
G E N E R A L I N F O R M A T I O N fContinued)
Fig, 2 Typical Cooling System Flow—Diesel Powered Engine

COOLING SYSTEM COMPONENTS AND F L O W - COOLANT RESERVE/OVERFLOW SYSTEM
DIESEL The coolant reserve/overflow system works In con
Coolant flow circuits for the 5.9L diesel engine are junction with the radiator pressure cap. I t utilizes
shown in (Fig. 2). thermal expansion and contraction of coolant to keep
The diesel cooling system consists of: a cross-flow coolant free of trapped air. I t provides a volume for
radiator, engine driven cooling fan, thermal viscous expansion and contraction of coolant. Refer to
fan drive, fan shroud, radiator pressure cap, thermo Description and Operation in this group for more
stat, a vertically mounted one-way check valve (jiggle information.
pin) at cylinder head, a bypass hose at thermostat,
coolant reserve/overflow system, transmission oil COOLANT
cooler (if equipped with an automatic transmission), The cooling system is designed around the coolant.
coolant, water pump, hoses and hose clamps. Coolant flows through the engine water jacket
Coolant is drawn from radiator into the water absorbing heat produced during engine operation.
pump. Water pump output is directed to the engine The coolant carries the heat to radiator and heater
oil cooler cavity of the cylinder block (Fig. 3). core. Here it is transferred to the ambient air pass
From the oil cooler cavity the coolant circulates ing through the radiator and heater core fins. The
around each cylinder. I t then crosses to the transfer coolant also removes heat from the automatic trans
(lift) pump side of the engine where it flows up into mission fluid in vehicles equipped with an automatic
the cylinder head through openings in top of the cyl transmission.
inder block (Fig. 3). Coolant flows past the valve
bridges (Fig. 4), to exhaust manifold side of engine RADIATOR PRESSURE CAP
and to thermostat. As coolant flows toward the ther Radiators are equipped with a pressure cap, which
mostat, it provides cooling for the injector nozzle. releases pressure at some point within a range of
Also refer to Thermostat Operation—5.9L Diesel 97-124 kPa (14-18 psi). The pressure relief point (in
Engine. This can be found In the Thermostat section pounds) is engraved on top of cap. See Description
of this group. and Operation i n this group for more information.
THERMOSTAT
The thermostat on all gas powered engines is
located beneath the thermostat housing at the front
of the intake manifold (Fig. 5) (Fig. 6).
THERMOSTAT
MACHINED GROOVE
J9207-14
Fig. 5 Thermostat—3£L V-6 or 5.2/5.9L
V-8 Gas Powered Engines
Fig. 3 Cylinder Block Coolant Routing—Diesel Engine TEMP. COOLANT
1. Coolant Flow from Cylinder Block

2. Coolant to Thermostat Housing
Fig. 4 Cylinder Head Coolant Routing—Diesel Engine

RADIATORS
The radiator used on all engines (both gas powered
and diesel) are of a cross-flow design with horizontal
tubes through the radiator core and vertical side tanks.
Aluminum cores with plastic side tanks are used on
all 3.9L V-6 and 5.2/5.9L V-8 engines. Copper-brass
cores are used with the 8.0L V-10 and diesel engines.
The radiator supplies sufficient heat transfer to
cool the engine and automatic transmission (if
equipped).
RUBBER LIP SEAL J9407-16
Fig. 6 Thermostat—8.0L V-10 Engine

BR COOLING SYSTEM 7-5
The thermostat of the 5.9L diesel engine is located BELT TENSION—ALL ENGINES
in the thermostat housing (Fig. 7)., The housing is Correct accessory drive belt tension is required to
located behind the generator mounting bracket, at be sure of optimum performance of belt driven engine
front of cylinder head. accessories. I f specific tension is not maintained, belt
slippage may cause; engine overheating, lack of
power steering assist, loss of air conditioning capac
ity, reduced generator output rate and greatly
reduced belt life.
It is not necessary to adjust belt tension on any
engine. A l l engines are equipped with an automatic
belt tensioner. The tensioner maintains correct belt
tension at all times. For other tensioner information
and removal/installation procedures, refer to Auto
matic Belt Tensioner proceeding in this group. Due to
use of this belt tensioner, do not attempt to use a belt
tension gauge on any engine.
THERMOSTAT—V-6, V-8, AND V-10

Fig. 7 Thermostat—5.9L Diesel—Typical The thermostat controls the operating temperature
Gas powered engines: The thermostat is a wax pel of the engine by controlling the amount of coolant
let driven, reverse poppet choke type (3.9L/5.2L/ flow to the radiator. The thermostat is closed below
5.9L), or moveable sleeve type (8.0L V-10). The wax 88°C (192°F). When the coolant reaches this temper
pellet is located In a sealed container at the spring ature, the thermostat begins to open, allowing cool
end of the thermostat. When heated, the pellet ant flow to the radiator. This provides quick engine
expands, overcoming closing spring tension and warmup and overall temperature control. The ther
water pump pressure to force the valve to open. Cool mostat is designed to provide a minimum engine
ant leakage Into the pellet container will cause the operating temperature of 88 to 93°C (192 to 199°F).
thermostat to fail in the open position. Thermostats It should be fully open for maximum coolant flow
very rarely stick. Do not attempt to free a thermostat during operation in hot ambient temperatures of
with a prying device. approximately 104°C (220°F). Above 104°C (220°F),
The same thermostat is used for winter and sum coolant temperature is controlled by the radiator, fan
mer seasons. An engine should not be operated with and ambient temperature.
out a thermostat, except for servicing or testing.
Operating without a thermostat causes longer engine THERMOSTAT—DIESEL
warmup time, unreliable warmup performance, The thermostat controls the operating temperature
increased exhaust emissions and crankcase condensa of the engine by controlling the amount of coolant
tion that can result i n sludge formation. flow to the radiator. When coolant temperature is
below 83°C (181°F), the thermostat is closed (Fig. 8).
CAUTION: Do not operate an engine without a When coolant temperature reaches 83°C (181°F),
thermostat, except for servicing or testing.' the thermostat begins to open allowing coolant flow
to the radiator. This provides quick engine warm-up
and overall temperature control. The thermostat is
ENGINE ACCESSORY DRIVE BELTS designed to provide a minimum engine operating
All vehicles are available with either a 3.9L V-6, a temperature of 83°C (181°F) and to be fully open for
5.2L V-8, two different 5.9L V-8 engines, an 8.0L V-10 maximum coolant flow at approximately 95°C
or a 5.9L in-line 6 cylinder diesel engine. (203°F). Above 95°C (203°F), coolant temperature is
The accessory drive components are operated by a controlled by the radiator, fan and ambient tempera
single, crankshaft driven, serpentine drive belt on all ture.
engines. An automatic belt tensioner is also used to The air bleeds (jiggle pins) that were used on the
maintain correct belt tension at all times. This is thermostats of diesel engines in previous years are
used on all engines. Refer to Automatic Belt Ten no longer used. They have been replaced by a verti
sioner proceeding in this group. cally mounted one-way check valve (jiggle pin) and a
rubber bypass hose. The check valve is used as a ser
vicing feature and will vent air when the system is
7 - 8 COOLING SYSTEM BR
AUTOMATIC TRANSMISSION OIL COOLERS—GAS

ENGINES
MMTER-TO-OIL COOLER
All gas powered models equipped with an auto
matic transmission are equipped with a transmission
oil cooler mounted internally within the radiator side
tank. This internal cooler is supplied as standard
equipment on all gas powered models equipped with
an automatic transmission.
The internal radiator oil cooler is not used with
the diesel engine.
Transmission oil is cooled when it passes through
this separate cooler. I n case of a leak in the internal
radiator mounted transmission oil cooler, engine cool
ant may become mixed with transmission fluid or
Fig. 8 Thermostat Operation-—5*91 Diesel—Typical transmission fluid may enter engine cooling system.
being filled. I t is also used to block the flow of cool Both cooling system and transmission should be
ant during engine operation (all coolant will pass drained and inspected i f the internal radiator
through the thermostat). mounted transmission cooler is leaking.
Water pressure (or flow) will hold the pin closed. Also refer to the section on Transmission Air-to-Oil
When the engine is off, the check valve will be in Coolers. This heavy duty air-to-oil cooler is an option
the open position. When the engine is operating, the on most engine packages. I t is supplied as standard
check valve will be in the closed position. equipment on both the 8.0L V-10 and 5.9L diesel
The check valve is located inside of a brass fitting. engines.
This fitting is threaded into the front of the cylinder
head (Fig. 9). I t is connected to the thermostat hous AIR-TO-OIL COOLER
ing with a rubber hose and screw-type clamps (Fig. 5.2/5.9L V-8 Gas Powered Engines: An optional
9). air-to-oil transmission oil cooler is available with
most engine packages. On the 5.2/5.9L V-8 engines,
this optional cooler is located between the radiator
and air conditioning condenser (Fig. 10).
UPPER RADIATOR TRANS. OIL
SUPPORT BRACKET COOLER
BOLT UPPER
BOLTS 121 COOLER

1
LOWER
Fig. 9 One-Way Check Valve (Jiggle Pin) Location MOUNTING
BOLT J9407-40
Fig. 10Air-To-Oil Cooler—3.9L V-6 or 5.2/5.9L V-8

Engines
BR C O O L i l i SYSTEM 7-7
8.0L V-10 Engine: The air-to-oil cooler is located
in front of and to the left side of the radiator (Fig.
11). This secondary cooler is supplied as standard
equipment on models equipped with the 8.0L V-10
engine and an automatic transmission.
RADIATOR
SUPPORT
OIL C O O L E R
MOUNTING
BOLTS (3) J9407-41
Fig. 11 Air-To-Oil Cooler—8.0L V-10 Engine

The oil coolers on all gas powered engines operate
in conjunction with the internal radiator mounted
main oil cooler. The transmission oil is routed
through the main cooler first, then the optional
cooler, before returning to the transmission.
AUTOMATIC TRANSMISSION OIL C O O L E R S -

DIESEL ENGINE
All diesel models equipped with an automatic QUICK-
transmission are equipped with both a main water- MOUNTING CONNECT
NUTS (2) FITTINGS (2) J9407-42
to-oil cooler and a separate air-to-oil cooler. Both cool
ers are supplied as standard equipment on diesel
Fig. 13 Air-To-Oil Cooler—Diesel Engine
engine powered models when equipped with an auto
matic transmission. 15) (Fig. 16). This belt tensioner will be used with all
Transmission oil is cooled when it passes through belt configurations, such as with or without power
these coolers. steering or air conditioning.
The main water-to-oil transmission oil cooler is
mounted to a bracket on the turbocharger side of the CAUTION: Do not attempt to check belt tension
engine (Fig. 12). with a belt tension gauge on vehicles equipped with
The air-to-oil cooler is located in front of and to the an automatic belt tensioner.
left side of the radiator (Fig. 13).
The diesel engine is not equipped with an internal On 3.9L V-6 or 5.2/5.9L V-8 LDC-gas engines, the
radiator mounted oil cooler. tensioner is equipped with an indexing arrow (Fig.
17) on back of tensioner and an indexing mark on
AUTOMATIC BELT TENSIONER tensioner housing. I f a new belt is being installed,
Drive belts on all engines are equipped with a arrow must be within approximately 3 mm (1/8 in.)
spring loaded automatic belt tensioner (Fig. 14) (Fig. of indexing mark (point B-) (Fig. 17). Belt is consid-
7 •8 COOLING SYSTEM BR
MOUNT.
BOLT
ACCESSORY
DRIVE BELT
3/8
SQUARE
HOLE
AUTOMATIC
BELT
TENSIONER J9307-59
Fig. 16 Belt Tensioner—5.9L Diesel—Typical

(non-A/C shown)
TENSIONER
J9219-15 ASSEMBLY
TENSIONER
MOUNTING NUT
Fig. 14 Beit Tensioner—3.9L V-6 or 5.2/5.9L V-8
LDC-Gas Engines
PULLEY
BOLT
TENSIONER
MOUNTING INDEXING
BOLT ARROW
INDEXING
MARK
TENSIONER J9307-64
J9207-17
Fig. 15 Belt Tensioner—5.9L HDC-Gas and 8.0L V-10
Engines Fig. 17 indexing Marks—3.9L V-6 or 5.2/5.9L V-8
LDC-Gas Engines
ered new i f it has been used 15 minutes or less. I f
this specification cannot be met, check for: • Misalignment of an engine accessory
• The wrong belt being installed (incorrect length/ • Belt incorrectly routed.
width) On 3.9L V-6 or 5.2/5.9L V-8 LDC-gas engines, a
• Worn bearings on an engine accessory (A/C com used belt should be replaced i f tensioner indexing
pressor, power steering pump, water pump, idler pul arrow has moved to point-A (Fig. 17). Tensioner
ley or generator) travel stops at point-A.
• A pulley on an engine accessory being loose
BR COOLING SYSTEM 7- 1
ENGINE BLOCK HEATERS
An optional engine block heater is available on all
models. The heater is equipped with a power cord.
The cord is attached to an engine compartment com
ponent with tie-straps. The heater warms the engine
providing easier engine starting and faster warm-up
in low temperatures. The heater is mounted i n a core
hole of the engine cylinder block (In place of a freeze
plug) with the heating element immersed i n engine
coolant. Connect the power cord to a grounded 110-
120 volt AC electrical outlet with a grounded three
wire extension cord.
WARNING: DO NOT OPERATE ENGINE UNLESS

BLOCK HEATER CORD HAS BEEN DISCONNECTED
FROM POWER SOURCE AND SECURED IN PLACE.
THE POWER CORD MUST BE SECURED IN ITS
RETAINING CLIPS AND ROUTED AWAY FROM
EXHAUST MANIFOLDS AND MOVING PARTS.
The 3.9L/5.2L/5.9L gas powered engine has the

block heater located on the right side of engine next
to the oil filter (Fig. 18). Fig. 19 Engine Block Heater—8.0L V-10 Engine
The 8.0L V-10 engine has the block heater located
on the right side of engine next to the engine oil dip
stick tube (Fig. 19).
The 5.9L diesel engine has the block heater located
on the right side of the engine below the exhaust
manifold (Fig. 20).
Fig. 20 Engine Block Heater—5.9L Diesel Engine

COOLANT PERFORMANCE
ETHYLENE-GLYCOL MIXTURES
The required ethylene-glycol (antifreeze) and water
mixture depends upon the climate and vehicle oper
ating conditions. The recommended mixture of 50/50
ethylene-glycol and water will provide protection
against freezing to -37 deg. C (-35 deg. F). The anti
freeze concentration must always be a minimum of
44 percent, year-round in all climates. If percentage
Fig. 18 Engine Block Heater—3.9U5.2U5.9L Gas is lower than 44 percent, engine parts may be
Powered Engine eroded by cavitation, and cooling system com
ponents may be severely damaged by corrosion.
Maximum protection against freezing is provided
with a 68 percent antifreeze concentration, which
7 - 10 COOLING SYSTEM
D E S C R I P T I O N A N D O P E R A T I O N {Continued)
prevents freezing down to -67.7 deg. C (-90 deg. F). A COOLANT SELECTION-ADDITIVES
higher percentage will freeze at a warmer tempera The presence of aluminum components in the cool
ture. Also, a higher percentage of antifreeze, can ing system requires strict corrosion protection. Main
cause the engine to overheat because the specific tain coolant at specified level with a mixture of
heat of antifreeze is lower than that of water. ethylene glycol based antifreeze and water. Only use
an antifreeze containing ALUGARD 340-2 ® such as
111 Percent Ethylene-Glycol—Should Not Be Used in Mopar Antifreeze. I f coolant becomes contaminated
Chrysler Vehicles or looses color, drain and flush cooling system and fill
Use of 100 percent ethylene-glycol will cause for with correctly mixed solution.
mation of additive deposits in the system, as the cor
rosion inhibitive additives in ethylene-glycol require CAUTION: Do not use coolant additives that are
the presence of water to dissolve. The deposits act as claimed to improve engine cooling.
insulation, causing temperatures to rise to as high as
149 deg. C (300) deg. F). This temperature is hot
enough to melt plastic and soften solder.. The RADIATOR PRESSURE CAP
increased temperature can result In engine detona Radiators are equipped with a pressure cap, which
tion. In addition, 100 percent ethylene-glycol freezes releases pressure at some point within a range of
at 22 deg. C (-8 deg. F ). 97-124 kPa (14-18 psi). The pressure relief point (in
pounds) is engraved on top of cap.
Propylene-glycol Formulations—Should lot le Used in The cooling system will operate at pressures
Chrysler Vehicles slightly above atmospheric pressure. This results in a
Propylene-glycol formulations do not meet higher coolant boiling point allowing increased radi
Chrysler coolant specifications. It's overall effec ator cooling capacity. The cap (Fig. 21) contains a
tive temperature range is smaller than that of ethyl spring-loaded pressure relief valve that opens when
ene-glycol. The freeze point of 50/50 propylene-glycol system pressure reaches release range of 97-124 kPa
and water is -32 deg. C (-26 deg. F). 5 deg. C higher (14-18 psi).
than ethylene-glycol's freeze point. The boiling point
(protection against summer boil-over) of propylene-
glycol is 125 deg. C (257 deg. F ) at 96.5 kPa (14 psi),
compared to 128 deg. C (263 deg. F) for ethylene-gly
col. Use of propylene-glycol can result in boil-over or
freeze-up in Chrysler vehicles, which are designed for
ethylene-glycol. Propylene glycol also has poorer heat
transfer characteristics than ethylene glycol. This
can increase cylinder head temperatures under cer
tain conditions.
Propylene-glycol/Ethylene-glycol Mixtures—Should Not Be

Used in Chrysler Vehicles
Propylene-glycol/ethylene-glycol Mixtures can
cause the destabilization of various corrosion inhibi Fig. 21 Radiator Pressure Cap and Filler Neck-
tors, causing damage to the various cooling system Typical
components. Also, once ethylene-glycol and propy A vent valve in the center of cap allows a small
lene-glycol based coolants are mixed in the vehicle, coolant flow through cap when coolant is below boil
conventional methods of determining freeze point will ing temperature. The valve is completely closed when
not be accurate. Both the refractive index and spe boiling point is reached. As the coolant cools, i t con
cific gravity differ between ethylene glycol and propy tracts and creates a vacuum in the cooling system.
lene glycol. This causes the vacuum valve to open and coolant in
the reserve/overflow tank to be drawn through its
CAUTION: Richer antifreeze mixtures cannot be connecting hose into radiator. I f the vacuum valve is
measured with normal field equipment and can stuck shut, the radiator hoses will collapse on cool-
cause problems associated with 100 percent ethyl down. Clean the vent valve (Fig. 21).
ene-glycol. A rubber gasket seals radiator filler neck to pre
vent leakage. This is done to keep system under
pressure. I t also maintains vacuum during coolant
cool-down allowing coolant to return from reserve/
overflow tank.
BR COOLING SYSTEM 7 - 11
DESCRIPTION AND OPERATION { C o n t i n u e d }

WATER PUMPS—V-6, V-8, AND V-10 ENGINES TOOLS DESIGNED FOR SERVICING THIS TYPE OF
A centrifugal water pump circulates coolant CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
through the water jackets, passages, Intake manifold, 6094) (Fig. 23). SNAP-ON CLAMP TOOL (NUMBER
radiator core, cooling system hoses and heater core. HPC-20) MAY BE USED FOR LARGER CLAMPS.
The pump is driven from the engine crankshaft by a ALWAYS WEAR SAFETY GLASSES WHEN SERVIC
drive belt. ING CONSTANT TENSION CLAMPS.
The water pump impeller Is pressed onto the rear
of a' shaft that rotates In a bearing pressed into the
CAUTION: A number or letter is stamped into the
water pump body. The body has a small hole for ven
tongue of constant tension clamps (Fig. 24). If
tilation. The water pump seals are lubricated by
replacement is necessary, use only an original
antifreeze in the' coolant mixture. Additional lubrica
equipment clamp with a matching number or letter.
tion is not necessary.
Ordinary worm gear type hose clamps (when
WATER PUMP—5.9L DIESEL equipped) can be removed with a straight screw
The diesel engine water pump draws coolant from driver or a hex socket. To prevent damage to
radiator outlet and circulates It through engine, hoses or clamps, the hose clamps should be
heater core and back to radiator Inlet. The crank tightened to 4 N»m (34 in. lbs.) torque. Do not
shaft pulley drives the water pump with a serpentine over tighten hose clamps.
drive belt (Fig. 22). An automatic belt tensioner (Fig. For all vehicles: In areas where specific routing
22) is used to prevent the belt from slipping. clamps are not provided, be sure that hoses are posi
tioned with sufficient clearance. Check clearance
from exhaust manifolds and pipe, fan blades, drive
belts and sway bars. Improperly positioned hoses can
be damaged, resulting in coolant loss and engine
overheating.
HOSE CLAMP HOSE
Fig. 22 Water Pump—5.9L Diesel—Typical (non-A/C

shown)
COOLING SYSTEM HOSES AND CLAMPS
J9207-36
Rubber hoses • route coolant to and from the radia
tor, intake manifold and heater core. Radiator lower Fig. 23 Hose Clamp Tool—Typical
hoses are spring-reinforced to prevent collapse. from
water pump suction at moderate and high engine COOLANT RESERVE/OVERFLOW SYSTEM
speeds. The coolant reserve/overflow system works i n con
Inspect the hoses at regular intervals. Replace junction with the radiator pressure cap. I t utilizes
hoses that are cracked, feel brittle when squeezed or thermal expansion and contraction of coolant to keep
swell excessively when system is pressurized. The coolant free of trapped air. I t provides a volume for
use of molded replacement hoses is recommended. expansion and contraction of coolant. I t also provides
When performing a hose inspection, inspect radiator a convenient and safe method for checking coolant
lower hose for proper position and condition of level and adjusting level at atmospheric pressure.
spring. This is done without removing the radiator pressure
cap. The system also provides some reserve coolant
WARNING: CONSTANT TENSION HOSE CLAMPS to the radiator to cover minor leaks and evaporation
ARE USED ON MOST COOLING SYSTEM HOSES. or boiling losses.
WHEN REMOVING OR INSTALLING, USE ONLY

TYPICAL COOLANT
CONSTANT RESERVE/OVERFLOW
TENSION HOSE TANK
CLAMP IGNITION CONTROL
MODULE (ICM)
TANK
MOUNTING
BOLTS (3)
ICM MOUNTING
BOLTS (2) J948D-21
Fig. 26 Coolant Reserve/Overflow TankS.OL V-10 Engine

TYPICAL
HOSE Refer to Coolant Level Check—Service, Deaeration
CLAMP and Radiator Pressure Cap sections in this group for
NUMBER/LETTER coolant reserve/overflow system operation and service.
LOCATION J9407-39
Should the reserve/overflow tank become coated with
Fig. 24 damp Number/Letter Location corrosion, it can be cleaned with detergent and water.
Rinse tank thoroughly before refilling cooling system as
As the engine cools, a vacuum is formed in the described in the Coolant section of this group.
cooling system of both the radiator and engine. Cool
ant will then be drawn from the coolant tank and VISCOUS FAN DRIVE
returned to a proper level in the radiator. The thermal viscous fan drive (Fig. 27) (Fig. 28)is a
On 3.9L/5.2L/5.9L gas engines and the 5.9L diesel silicone-fluid- filled coupling used to connect the fan
engine, the coolant reserve/overflow tank is mounted blades to the water pump shaft. The coupling allows
to the side of the fan shroud (Fig. 25). On the 8.0L the fan to be driven in a normal manner. This is
V-10 engine the tank is mounted to right inner done at low engine speeds while limiting the top
fender (Fig. 26). speed of the fan to a predetermined maximum level
T-SLOTS at higher engine speeds.
FAN BLADE WATER WATER PUMP
ASSEMBLY PUMP
PULLEY
THREADED
NUT
COOLANT \
RESERVE/OVERFLOW
ALIGNMENT
PIN
THREADED SHAFT CRANKSHAFT
FAN (WATER PUMP HUB) PULLEY
SHROUD J9407-36
VISCOUS FAN DRIVE
J9307-32
Fig. 25 Coolant Reserve/Overflow Tank—All Except
8.0L V-10 Engine
Fig. 27 Viscous Fan Drive—Gas Engines
BR COOLING SYSTEM 7 -13
THREADED
Once the engine has cooled, the radiator discharge
temperature will drop. The bimetallic coil again
reacts and the fan speed is reduced to the previous
disengaged speed.
CAUTION: - Some engines equipped with serpentine

drive belts have reverse rotating fans and viscous fan
drives. They are marked with the word REVERSE to
designate their usage. Installation of the wrong fan or
viscous fan drive can result in engine overheating.
CAUTION: If the viscous fan drive is replaced because

of mechanical damage, the cooling fan blades should
also be inspected. Inspect for fatigue cracks, loose
blades, or loose rivets that could have resulted from
excessive vibration. Replace fan blade assembly If any
of these conditions are found. Also inspect water pump
bearing and shaft assembly for any related damage due
to a viscous fan drive malfunction.
Fig. 28 Viscous Fan Drive—Diesel Engine DIAGNOSIS AND T E S T I N G

A thermostatic bimetallic spring coil is located on
the front face of the viscous fan drive unit (a typical ON-BOARD DIAGNOSTICS (OBD)
viscous unit is shown In (Fig. 29). This spring coil
FOR CERTAIN COOLING SYSTEM
reacts to the temperature of the radiator discharge
COMPONENTS
air. I t engages the viscous fan drive for higher fan
The powertrain control module (PCM) has been
speed i f the air temperature from the radiator rises
programmed to monitor certain cooling system com
above a certain point. Until additional engine cooling
ponents on gasoline powered engines only:
is necessary the fan will remain at a reduced rpm
• I f the engine has remained cool for too long a
regardless of engine speed.
period, such as with a stuck open thermostat, a Diag
MOUNTING NUT nostic Trouble Code (DTC) number 17 can be
T O WATER PUMP observed at the malfunction indicator lamp. This
lamp is displayed on the instrument panel as the
CHECK ENGINE lamp (Fig. 30). DTC number I f
is not used with diesel powered engines.
Fig. 29 Viscous Fan Drive—Typical

Only when sufficient heat is present, will the vis
cous fan drive engage. This is when the air flowing
through the radiator core causes a reaction to the
bimetallic coil. It then increases fan speed to provide
the necessary additional engine cooling. Fig. 30 Check Engine Lamp Location

I f the problem Is sensed in a monitored circuit • I f the lamp flashes 1 time, pauses and flashes 7
often enough to indicate an actual problem, a DTC is more times, a flashing Diagnostic Trouble Code
stored. The DTC will be stored In the PCM memory (DTC) number 17 is indicated.
for eventual display to the service technician. I f the After any stored DTC information has been observed,
problem Is repaired or ceases to exist, the PCM can the display will end with a flashing DTC number 55.
cels the DTC after 51 engine starts. This will indicate the end of all stored information.
Certain criteria must be met for a DTC to be
entered Into PCM memory. The criteria may be a ERASING TROUBLE CODES
specific range of engine rpm, engine temperature After the problem has been repaired, use the DRB
and/or Input voltage to the PCM. scan tool to erase a DTC. Refer to the appropriate
A DTC Indicates that the PCM has recognized an Powertrain Diagnostic Procedures service manual for
abnormal signal in a circuit or the system. A DTC operation of the DRB scan tool.
may indicate the result of a failure, but never Iden
tify the failed component directly. DRB SCAN TOOL
It is possible that a DTC for a monitored circuit may For operation of the DRB scan tool, refer to the appro
not be entered into memory even though a malfunction priate Powertrain Diagnostic Procedures service manual.
has occurred. Refer to On- Board Diagnostics (OBD) in
Group 14, Fuel Systems for additional information. PRELIMINARY CHECKS
ACCESSING DIAGNOSTIC TROUBLE CODES ENGINE COOLING SYSTEM OVERHEATING

A stored Diagnostic Trouble Code (DTC) can be dis Establish what driving conditions caused the com
played by cycling the ignition key On-Off-On-Off-On plaint. Abnormal loads on the cooling system such as
within three seconds and observing the malfunction the following may be the cause:
indicator lamp. This lamp is displayed on the instru (1) PROLONGED IDLE, VERY HIGH AMBIENT
ment panel as the CHECK ENGINE lamp (Fig. 30). TEMPERATURE, SLIGHT TAIL WIND AT IDLE,
They can also be displayed through the use of the SLOW TRAFFIC, TRAFFIC JAMS, HIGH SPEED
Diagnostic Readout Box (DRB) scan tool. The DRB con OR STEEP GRADES.
nects to the data link connector (Fig. 31) located at the Driving techniques that avoid overheating are:
lower edge of instrument panel near the steering column. • Idle with A/C off when temperature gauge is at
For operation of the DRB, refer to the appropriate Pow- end of normal range.
ertrain Diagnostic Procedures service manual. • Increasing engine speed for more air flow is rec
ommended.
16-WAY DATA (2) TRAILER TOWING:
LINK CONNECTOR Consult Trailer Towing section of owners manual.
Do not exceed limits.
(3) AIR CONDITIONING; ADD-ON OR AFTER
MARKET:
A maximum cooling package should have been
ordered with vehicle i f add-on or after market A/C is
installed. I f not, maximum cooling system compo
nents should be installed for model involved per
manufacturer's specifications.
(4) RECENT SERVICE OR ACCIDENT REPAIR:
Determine i f any recent service has been per
formed on vehicle that may effect cooling system.
This may be:
805dd852 • Engine adjustments (incorrect timing)
Fig. 31 Data Link Connector
• Slipping engine accessory drive belt(s)
EXAMPLES: • Brakes (possibly dragging)
• I f the lamp (Fig. 30) flashes 1 time, pauses and « Changed parts. Incorrect water pump or pump rotat
flashes 2 more times, a flashing Diagnostic Trouble ing in wrong direction due to belt not correctly routed
Code (DTC) number 12 is indicated. I f this code is • Reconditioned radiator or cooling system refill
observed, i t is indicating that the battery has been ing (possibly under filled or air trapped in system).
disconnected within the last 50 key-on cycles. I t
could also indicate that battery voltage has been dis NOTE: If investigation reveals none of the previous
connected to the PCM. In either case, other DTCs items as a cause for an engine overheating complaint,
may have been erased. refer to following Cooling System Diagnosis charts.
BR — — — COOLING SYSTEM 7 -15
COOLING SYSTEM DIAGNOSIS

TEMPERATURE GAUGE 1. Has a Diagnostic Trouble 1. Refer to On-Board Diagnostics in the

READS LOW Code (DTC) number 17 been service manual text. Replace thermostat
set indicating a stuck open if necessary. If a Diagnostic Trouble
engine thermostat? Code (DTC) number 17 has not been set,
the problem may be with the temperature
gauge.
2. Is the temperature gauge 2. Check the engine temperature sensor
(if equipped) connected to the connector in the engine compartment.
temperature gauge coolant Refer to Group 8E. Repair as necessary.
sensor on the engine?
3. Is the temperature gauge 3. Check gauge operation. Refer to
(if equipped) operating OK? Group 8E. Repair as necessary.
4. Coolant level low in cold 4. Check coolant level in the coolant
ambient temperatures reserve/overflow tank and the radiator.
accompanied with poor heater Inspect system for leaks. Repair leaks as
performance. necessary. Refer to the Coolant section
of the manual text for WARNINGS and
precautions before removing the radiator
cap.
5. Improper operation of internal 5. Inspect heater and repair as necessary.
heater doors or heater Refer to Group 24, Heating and Air
controls. Conditioning for procedures.
TEMPERATURE GAUGE 1. Trailer is being towed, a steep hill 1. This may be a temporary condition and
READS HIGH OR ENGINE is being climbed, vehicle is repair is not necessary. Turn off the air
COOLANT WARNING LAMP operated in slow moving traffic, conditioning and attempt to drive the vehicle
ILLUMINATES. COOLANT or engine is being idled with very without any of the previous conditions.
MAY OR MAY NOT BE high ambient (outside) Observe the temperature gauge. The gauge
LOST OR LEAKING FROM temperatures and the air should return to the normal range. If the
COOLING SYSTEM conditioning is on. Higher gauge does not return to normal range,
altitudes could aggravate these determine the cause for overheating and
conditions. repair. Refer to POSSIBLE CAUSES
(numbers 2 through 20).
2. Is temperature gauge 2. Check gauge. Refer to Group 8E. Repair as
(if equipped) reading correctly? necessary.
3. Is temperature warning lamp 3. Check warning lamp operation. Refer to
(if equipped) illuminating Group 8E. Repair as necessary.
unnecessarily?
4. Coolant low in coolant 4. Check for coolant leaks and repair as
reserve/overflow tank and necessary. Refer to Testing Cooling System
radiator? For Leaks in this group.
5. Pressure cap not installed tightly. 5. Tighten cap.
If cap is loose, boiling point of
coolant will be lowered. Also refer
to the following step 6.
6. Poor seals at radiator cap. 6. (a) Check condition of cap and cap seals.
Refer to Radiator Cap. Replace cap if
necessary.
(b) Check condition of radiator filler neck. If
t neck is bent or damaged, replace
radiator.
J9507-41
COOLING SYSTEM DIAGNOSIS—ALL EXCEPT DIESEL
TEMPERATURE GAUGE . Coolant level low in radiator but 7. (a) Check condition of radiator cap and cap
READS HIGH OR ENGINE not in coolant reserve/overflow seals. Refer to Radiator Cap in this
COOLANT WARNING LAMP tank. This means the radiator is group. Replace cap if necessary.
ILLUMINATES. COOLANT not drawing coolant from the (b) Check condition of radiator filler neck. If
MAY OR MAY NOT BE LOST coolant reserve/overflow tank as neck is bent or damaged, replace
OR LEAKING FROM the engine cools. As the engine radiator.
COOLING SYSTEM - CONT. cools, a vacuum is formed in the
(c) Check the condition of the hose from the
cooling system of the engine and
radiator to the coolant tank. It should fit
radiator. If radiator cap seals are
tight at both ends without any kinks or
defective, or cooling system has
tears. Replace hose if necessary.
leaks, a vacuum can not be
formed. (d) Check coolant reserve/overflow tank and
tank hoses for blockage. Repair as
necessary.
8. Freeze point of antifreeze not 8. Check antifreeze. Refer to Coolant section
correct. Mixture may be too rich. of this group. Adjust antifreeze-to-water
ratio as required.
9. Coolant not flowing through 9. Check for coolant flow at radiator filler neck
system. with some coolant removed, engine warm
and thermostat open. Coolant should be
observed flowing through radiator. If flow is
not observed, determine reason for lack of
flow and repair as necessary.
10. Radiator or A/C condenser fins 10. Clean insects or debris. Refer to Radiator
are dirty or clogged. Cleaning in this group.
11. Radiator core is corroded or 11. Have radiator re-cored or replaced.
plugged.
12. Aftermarket A/C installed without 12. Install proper radiator.
proper radiator.
13. Fuel or ignition system problems. 13. Refer to Fuel and Ignition System groups
for diagnosis. Also refer to the appropriate
Powertrain Diagnostic Procedures service
manual for operation of the DRB scan tool.
14. Dragging brakes. 14. Check and correct as necessary. Refer to
Group 5, Brakes in the manual text.
15. Bug screen is being used 15. Remove bug screen.
reducing airflow.
16. Thermostat partially or completely 16. Check thermostat operation and replace
shut. This is more prevalent on as necessary. Refer to Thermostats in this
high mileage vehicles. group.
17. Thermal viscous fan drive not 17. Check fan drive operation and replace if
operating properly. necessary. Refer to Viscous Fan Drive in
this group.
18. Cylinder head gasket leaking. 18. Check for cylinder head gasket leaks.
Refer to Testing Cooling System For
Leaks in this group. For repair, refer to
Group 9, Engines.
19. Heater core leaking. 19. Check heater core for leaks. Refer to
Group 24, Heating and Air Conditioning.
Repair as necessary.
J9507-50
BR — — — COOLING SYSTEM 7 -17
COOLING SYSTEM DIAGNOSIS—ALL EXCEPT DIESEL—CONTINUED
TEMPERATURE GAUGE 1. During cold weather operation, 1. A normal condition. No correction is

READING IS INCONSISTENT with the heater blower in the high necessary.
(FLUCTUATES, CYCLES OR position, the gauge reading may
IS ERRATIC) drop slightly.
2. Temperature gauge or engine 2. Check operation of gauge and repair if
mounted gauge sensor defective necessary. Refer to Group 8E, Instrument
or shorted. Also, corroded or Panel And Gauges.
loose wiring in this circuit.
3. Gauge reading rises when vehicle 3. A normal condition. No correction is
is brought to a stop after heavy necessary. Gauge reading should return to
use (engine still running). normal range after vehicle is driven.
4. Gauge reading high after re 4. A normal condition. No correction is
starting a warmed-up (hot) necessary. The gauge should return to
engine. normal range after a few minutes of engine
operation.
5. Coolant level low in radiator (air 5. Check and correct coolant leaks. Refer to
will build up in the cooling system Testing Cooling System For Leaks in this
causing the thermostat to open group.
late).
6. Cylinder head gasket leaking 6. (a) Check for cylinder head gasket leaks
allowing exhaust gas to enter with a commercially available Block
cooling system causing Leak Tester. Repair as necessary.
thermostat to open late.
(b) Check for coolant in the engine oil.
Inspect for white steam emitting from
exhaust system. Repair as necessary.
7. Water pump impeller loose on
7. Check water pump and replace as
shaft.
necessary. Refer to Water Pumps in this
group.
8. Loose accessory drive belt (water 8. Refer to Engine Accessory Drive Belts in
pump slipping). this group. Check and correct as
necessary.
9. Air leak on the suction side of 9. Locate leak and repair as necessary.
water pump allows air to build up
in cooling system causing
PRESSURE CAP IS 1. Pressure relief valve in radiator 1. Check condition of radiator cap and cap
BLOWING OFF STEAM cap is defective. seals. Refer to Radiator Caps in this
AND/OR COOLANT TO group. Replace cap as necessary.
COOLANT TANK.
TEMPERATURE GAUGE
READING MAY BE ABOVE
NORMAL BUT NOT HIGH.
COOLANT LEVEL MAY BE
HIGH IN COOLANT
RESERVE/OVERFLOW TANK
COOLANT LOSS TO THE 1. Coolant leaks in radiator, 1. Pressure test and repair as necessary.
GROUND WITHOUT cooling system hoses, water Refer to Testing Cooling System For
PRESSURE CAP BLOWOFF. pump or engine. Leaks in this group.
GAUGE IS READING HIGH
OR HOT
J9507-51
COOLING S Y S T E M DIAGNOSIS—ALL EXCEPT DIESEL—CONTINUED
DETONATION OR PRE- 1. Engine overheating. 1. Check reason for overheating and repair
IGNITION (NOT CAUSED BY as necessary.
IGNITION SYSTEM). GAUGE 2. Freeze point of antifreeze not 2. Check antifreeze. Refer to the Coolant
MAYOR MAY NOT BE correct. Mixture is too rich or too section of this group. Adjust antifreeze-
READING HIGH lean. to-water ratio as required.
HOSE OR HOSES 1. Vacuum created in cooling 1. (a) Radiator cap relief valve stuck. Refer
COLLAPSE WHEN ENGINE system on engine cool-down is to Radiator Cap in this group.
IS COOLING not being relieved through Replace if necessary.
coolant reserve/overflow (b) Hose between coolant
system. reserve/overflow tank and radiator is
kinked. Repair as necessary.
(c) Vent at coolant reserve/overflow tank
is plugged. Clean vent and repair as
necessary.
(d) Reserve/overflow tank is internally
blocked or plugged. Check for
blockage and repair as necessary.
NOISY FAN 1. Fan blades loose. 1. Replace fan blade assembly. Refer to
Cooling System Fans in this group.
2. Fan blades striking a 2. Locate point of fan blade contact and
surrounding object. repair as necessary.
3. Air obstructions at radiator or air 3. Remove obstructions and/or clean debris
conditioning condenser. or insects from radiator or A/C
condenser.
4. Thermal viscous fan drive has 4. Replace fan drive. Bearing is not
defective bearing. serviceable. Refer to Viscous Fan Drive
in this group.
5. A certain amount of fan noise 5. Refer to Viscous Fan Drive in this group
(roaring) may be evident on for an explanation of normal fan noise.
models equipped with a thermal
viscous fan drive. Some of this
noise is normal.
INADEQUATE AIR 1. Radiator and/or A/C condenser is 1. Remove restriction and/or clean as
CONDITIONER restricted, obstructed or dirty necessary. Refer to Radiator Cleaning in
PERFORMANCE (COOLING (insects, leaves etc.). this group.
SYSTEM SUSPECTED) 2. Thermal viscous fan drive is free 2. Refer to Viscous Fan Drive for diagnosis.
wheeling. Repair as necessary.
3. Engine is overheating (heat may 3. Correct overheating condition. Refer to
be transferred from radiator to text in Group 7, Cooling.
A/C condenser. High underhood
temperatures due to engine
overheating may also transfer
heat to A/C components).
4. Some models with certain 4. Check for missing or damaged air seals
engines are equipped with air and repair as necessary.
seals at the radiator and/or A/C
condenser. If these seals are
missing or damaged, not enough
air flow will be pulled through the
radiator and A/C condenser.
J9507-52
BR — — — COOLING SYSTEM 7 - 19
COOLING S Y S T E M DIAGNOSIS—ALL EXCEPT DIESEL—CONTINUED
INADEQUATE HEATER 1. Has a diagnostic trouble code 1. Refer to On-Board Diagnostics in the
PERFORMANCE. (DTC) number 17 been set? manual text and replace thermostat if
THERMOSTAT FAILED IN necessary.
OPEN POSITION 2. Coolant level low. 2. Refer to Testing Cooling System For
Leaks in the manual text. Repair as.
. necessary.
3. Obstructions in heater hose 3. Remove heater hoses at both ends and
fittings at engine. check for obstructions. Repair as
necessary.
4. Heater hose kinked. 4. Locate kinked area and repair as
necessary.
5. Some models with certain 5. Refer to Group 24, Heating and Air
engines are equipped with a Conditioning for diagnosis. Repair as
water control valve located on necessary.
one of the heater hoses. This
valve may be defective.
6. Water pump is not pumping 6. Refer to Water Pumps in this group.
water to heater core. When the Repair as necessary. If a slipping belt is
engine is fully warmed up, both - detected, refer to Engine Accessory Drive
heater hoses should be hot to Belts in this group. Repair as necessary.
the touch. If only one of the
hoses is hot, the water pump
may not be operating correctly.
The accessory drive belt may
also be slipping causing poor
water pump operation.
HEAT ODOR 1. Various heat shields are used at 1. Locate missing shields and replace or
certain drive line components. repair as necessary.
One or more of these shields
may be missing.
2. Is temperature gauge reading 2. Refer to the previous Temperature
above the normal range? Gauge Reads High in these Diagnosis
Charts. Repair as necessary.
3. Is cooling fan operating 3. Refer to Cooling System Fan in this
correctly? group for diagnosis. Repair as necessary.
4. Has undercoating been applied 4. Clean undercoating as necessary.
to any unnecessary component?
5. Engine may be running rich 5. Refer to the DRB scan tool and the
causing the catalytic converter appropriate Powertrain Diagnostic
to overheat. Procedures service manual. Repair as
necessary.
POOR DRIVEABILITY 1. For proper driveability, good 1. Refer to On-Board Diagnostics in this
(THERMOSTAT POSSIBLY vehicle emissions and for group. DTCs may also be checked using
STUCK OPEN). GAUGE preventing build-up of engine oil the DRB scan tool. Refer to the proper
MAY BE READING LOW sludge, the thermostat must be Powertrain Diagnostics Procedures
operating properly. Has a service manual for checking the
diagnostic trouble code (DTC) thermostat using the DRB scan tool.
number 17 been set? Replace thermostat if necessary.
J9507-53
7 - 20 COOLING SYSTEM — BR
COOLING SYSTEM DIAGNOSIS—ALL EXCEPT DIESEL—CONTINUED
Condition Possible Causes Correction
STEAM IS COMING FROM 1. During wet weather, moisture 1. Occasional steam emitting from this
FRONT OF VEHICLE NEAR (snow, ice or rain condensation) area is normal. No repair is necessary.
GRILL AREA WHEN on the radiator will evaporate
WEATHER IS WET, ENGINE when the thermostat opens.
IS WARMED UP AND This opening allows heated
RUNNING, AND VEHICLE IS water into the radiator. When
STATIONARY. the moisture contacts the hot
TEMPERATURE GAUGE IS radiator, steam may be emitted.
IN NORMAL RANGE This usually occurs in cold
weather with no fan or airflow
to blow it away.
COOLANT COLOR 1. Coolant color is not necessarily 1. Refer to Coolant in this group for
an indication of adequate antifreeze tests. Adjust antifreeze-to-
corrosion or temperature water ratio as necessary.
protection. Do not rely on
coolant color for determining
condition of coolant.
COOLANT LEVEL CHANGES 1. Level changes are to be 1. A normal condition. No repair is
IN COOLANT RESERVE/ expected as coolant volume necessary.
OVERFLOW TANK. fluctuates with engine
TEMPERATURE GAUGE temperature. If the level in the
IS IN NORMAL RANGE tank was between the FULL
and ADD marks at normal
engine operating temperature,
the level should return to
within that range after operation
at elevated temperatures.
J9507-55
BR . . . COOLING SYSTEM 7 - 21
COOLING SYSTEM DIAGNOSIS—DIESEL ENGINE

TEMPERATURE GAUGE 1. Diesel engines, due to their 1. The low gauge reading may be normal.
READS LOW inherent efficiency are slower Refer to thermostats in the manual text
to warm up than gasoline for information. See Thermostat
powered engines, and will Diagnosis - Diesel Engine.
operate at lower temperatures
when the vehicle is unloaded.
2. Is the temperature gauge 2. Check the engine temperature sensor
connected to the temperature connector in the engine compartment.
gauge coolant sensor on the Refer to Group 8E. Repair as necessary.
engine?
3. Is the temperature gauge 3. Check gauge operation. Refer to
operating OK? Group 8E. Repair as necessary.
4. Coolant level low in cold 4. Check coolant level in the coolant
ambient temperatures reserve/overflow tank and the radiator.
accompanied with poor heater Inspect system for leaks. Repair leaks as
performance. necessary. Refer to the Coolant section
of the manual text for WARNINGS and
precautions before removing the radiator
cap.
5. Improper operation of internal 5. Inspect heater and repair as necessary.
heater doors or heater Refer to Group 24, Heating and Air
controls. Conditioning for procedures.
TEMPERATURE GAUGE 1. Trailer is being towed, a steep hill 1. This may be a temporary condition and
READS HIGH. COOLANT is being climbed, vehicle is repair is not necessary. Turn off the air
MAY OR MAY NOT BE operated in slow moving traffic, conditioning and attempt to drive the vehicle
LOST OR LEAKING FROM or engine is being idled with very without any of the previous conditions.
COOLING SYSTEM high ambient (outside) Observe the temperature gauge. The gauge
temperatures and the air should return to the normal range. If the
conditioning is on. Higher gauge does not return to normal range,
altitudes could aggravate these determine the cause for overheating and
conditions. repair. Refer to POSSIBLE CAUSES
(numbers 2 through 17).
2. Is temperature gauge 2. Check gauge. Refer to Group 8E. Repair as
reading correctly? necessary.
3. Coolant low in coolant 3. Check for coolant leaks and repair as
reserve/overflow tank and necessary. Refer to Testing Cooling System
radiator? For Leaks in this group.
4. Pressure cap not installed tightly. 4. Tighten cap.
If cap is loose, boiling point of
coolant will be lowered. Also refer
to the following step 5.
5. Poor seals at radiator cap. 5. (a) Check condition of cap and cap seals.
Refer to Radiator Cap. Replace cap if
necessary.
(b) Check condition of radiator filler neck. If
neck is bent or damaged, replace
radiator.
J9507-57
COOLING SYSTEM DIAGNOSIS—DIESEL ENGINE—CONTINUED

TEMPERATURE GAUGE 6. Coolant level low in radiator but 6. (a) Check condition of radiator cap and cap
READS HIGH. COOLANT not in coolant reserve/overflow seals. Refer to Radiator Cap in this
MAY OR MAY NOT BE LOST tank. This means the radiator is group. Replace cap if necessary.
OR LEAKING FROM not drawing coolant from the (b) Check condition of radiator filler neck. If
COOLING SYSTEM - CONT. coolant reserve/overflow tank as neck is bent or damaged, replace
the engine cools. As the engine radiator.
cools, a vacuum is formed in the
cooling system of the engine and (c) Check the condition of the hose from
radiator. If radiator cap seals are the radiator to the coolant tank. It should
defective, or cooling system has fit tight at both ends without any kinks or
leaks, a vacuum can not be tears. Replace hose if necessary.
formed. (d) Check coolant reserve/overflow tank
and tank hoses for blockage. Repair as
necessary.
7. Freeze point of antifreeze not 7. Check antifreeze. Refer to Coolant section
correct. Mixture may be too rich. of this group. Adjust antifreeze-to-water
ratio as required.
8. Coolant not flowing through 8. Check for coolant flow at radiator filler neck
system. with some coolant removed, engine warm
and thermostat open. Coolant should be
observed flowing through radiator. If flow is
not observed, determine reason for lack of
flow and repair as necessary.
9. Radiator or A/C condenser fins 9. Clean insects or debris. Refer to Radiator

are dirty or clogged. Cleaning in this group.
10. Radiator core is corroded or 10. Have radiator re-cored or replaced.
plugged.
11. Aftermarket A/C installed without 11. Install proper radiator.
proper radiator.
12. Dragging brakes. 12. Check and correct as necessary. Refer to
Group 5, Brakes in the manual text.
13. Bug screen is being used 13. Remove bug screen.
reducing airflow.
14. Thermostat partially or completely 14. Check thermostat operation and replace
shut. This is more prevalent on as necessary. Refer to Thermostats in this
high mileage vehicles. group.
15. Thermal viscous fan drive not 15. Check fan drive operation and replace if
operating properly. necessary. Refer to Viscous Fan Drive in
this group.
16. Cylinder head gasket leaking. 16. Check for cylinder head gasket leaks.
Refer to Testing Cooling System For
Leaks in this group. For repair, refer to
Group 9, Engines.
17. Heater core leaking. 17. Check heater core for leaks. Refer to
Group 24, Heating and Air Conditioning.
Repair as necessary.
J9507-58
BR — — — — — — COOLING SYSTEM 7 - 23

TEMPERATURE GAUGE 1. During cold weather operation, 1. A normal condition. No correction is

READING IS INCONSISTENT with the heater blower in the high necessary.
(FLUCTUATES, CYCLES OR position, the gauge reading may
IS ERRATIC) drop slightly. Fluctuation is also
influenced by loads, outside
temperature and extended idle
time with diesel engines.
2. Temperature gauge or engine 2. Check operation of gauge and repair if
mounted gauge sensor defective necessary. Refer to Group 8E, Instrument
or shorted. Also, corroded or Panel And Gauges.
loose wiring in this circuit.
3. Gauge reading rises when vehicle 3. A normal condition. No correction is
is brought to a stop after heavy necessary. Gauge reading should return to
use (engine still running). normal range after vehicle is driven.
4. Gauge reading high after re 4. A normal condition. No correction is
starting a warmed-up (hot) necessary. The gauge should return to
engine. normal range after a few minutes of engir 5
operation.
5. Coolant level low in radiator (air 5. Check and correct coolant leaks. Refer to
will build up in the cooling system Testing Cooling System For Leaks in this
causing the thermostat to open group.
late).
6. Cylinder head gasket leaking 6. (a) Check for cylinder head gasket leaks
allowing exhaust gas to enter with a commercially available Block
cooling system causing Leak Tester. Repair as necessary.
thermostat to open late. (b) Check for coolant in the engine oil.
Inspect for white steam emitting from
exhaust system. Repair as necessary.
7. Water pump impeller loose on 7. Check water pump and replace as
shaft. necessary. Refer to Water Pumps in this
group.
8. Loose accessory drive belt (water 8. Refer to Engine Accessory Drive Belts in
pump slipping). this group. Check and correct as
necessary.
9. Air leak on the suction side of 9. Locate leak and repair as necessary.
water pump allows air to build up
in cooling system causing
PRESSURE CAP IS 1. Pressure relief valve in radiator 1. Check condition of radiator cap and cap
BLOWING OFF STEAM cap is defective. seals. Refer to Radiator Caps in this
AND/OR COOLANT TO group. Replace cap as necessary.
COOLANT TANK.
TEMPERATURE GAUGE
READING MAY BE ABOVE
NORMAL BUT NOT HIGH.
COOLANT LEVEL MAY BE
HIGH IN COOLANT
RESERVE/OVERFLOW TANK
COOLANT LOSS TO THE 1. Coolant leaks in radiator, 1. Pressure test and repair as necessary.
GROUND WITHOUT PRES cooling system hoses, water Refer to Testing Cooling System For
SURE CAP BLOWOFF. GAUGE pump or engine. Leaks in this group.
IS READING HIGH OR HOT
J9507-59
7 - 24 COOLING SYSTEM — — — BR

HOSE OR HOSES 1. Vacuum created in cooling 1. (a) Radiator cap relief valve stuck. Refer
COLLAPSE WHEN ENGINE system on engine cool-down is to Radiator Cap in this group.
IS COOLING not being relieved through . Replace if necessary.
coolant reserve/overflow (b) Hose between coolant
system. reserve/overflow tank and radiator is
kinked. Repair as necessary.
(c) Vent at coolant reserve/overflow tank
is plugged. Clean vent and repair a:
necessary.
(d) Reserve/overflow tank is internally
blocked or plugged. Check for
blockage and repair as necessary.
NOISY FAN 1. Fan blades loose. 1. Replace fan blade assembly. Refer to
Cooling System Fans in this group.
2. Fan blades striking a 2. Locate point of fan blade contact and
surrounding object. repair as necessary.
3. Air obstructions at radiator or air 3. Remove obstructions and/or clean debris
conditioning condenser. or insects from radiator or A/C
condenser.
4. Thermal viscous fan drive has 4. Replace fan drive. Bearing is not
defective bearing. serviceable. Refer to Viscous Fan Drive
in this group.
5. A certain amount of fan noise 5. Refer to Viscous Fan Drive in this group
(roaring) may be evident on for an explanation of normal fan noise.
models equipped with a thermal
viscous fan drive. Some of this
noise is normal.
INADEQUATE AIR 1. Radiator and/or A/C condenser is 1. Remove restriction and/or clean as
CONDITIONER restricted, obstructed or dirty necessary. Refer to Radiator Cleaning in
PERFORMANCE (COOLING (insects, leaves etc.). this group.
SYSTEM SUSPECTED) 2. Thermal viscous fan drive is free 2. Refer to Viscous Fan Drive for diagnosis.
wheeling. Repair as necessary.
3. Engine is overheating (heat may 3. Correct overheating condition. Refer to
be transferred from radiator to text in Group 7, Cooling.
A/C condenser. High underhood
temperatures due to engine
overheating may also transfer
heat to A/C components).
4. Some models with certain 4. Check for missing or damaged air seals
engines are equipped with air and repair as necessary.
seals at the radiator and/or A/C
condenser. If these seals are
missing or damaged, not enough
air flow will be pulled through the
radiator and A/C condenser.
J9507-60
BR • • —— — • — — COOLING SYSTEM 7 - 25
INADEQUATE HEATER 1. Diesel engines, due to their 1. The low gauge reading may be normal.
PERFORMANCE. MAYBE inherent efficiency are slower to Refer to Thermostats in the manual text
ACCOMPANIED BY LOW warm up than gasoline powered for information. See Thermostat
GAUGE READING engines, and will operate at Diagnosis - Diesel Engine.
lower temperatures when the
vehicle is unloaded.
2. Coolant level low. 2. Refer to Testing Cooling System For
Leaks in the manual text. Repair as
necessary.
3. Obstructions in heater hose 3. Remove heater hoses at both ends and
fittings at engine. check for obstructions. Repair as
necessary.
4. Heater hose kinked. 4. Locate kinked area and repair as
necessary.
5. Water pump is not pumping 5. Refer to Water Pumps in this group.
water to heater core. When the Repair as necessary. If a slipping belt is
engine is fully warmed up, both detected, refer to Engine Accessory Drive
heater hoses should be hot to Belts in this group. Repair as necessary.
the touch. If only one of the
hoses is hot, the water pump
may not be operating correctly.
The accessory drive belt may
also be slipping causing poor
water pump operation.
HEAT ODOR 1. Various heat shields are used at 1. Locate missing shields and replace or
certain drive line components. repair as necessary.
One or more of these shields
may be missing.
2. Is temperature gauge reading 2. Refer to the previous Temperature
above the normal range? Gauge Reads High in these Diagnosis
Charts. Repair as necessary.
3. Is cooling fan operating 3. Refer to Cooling System Fan in this
correctly? group for diagnosis. Repair as necessary.
4. Has undercoating been applied 4. Clean undercoating as necessary.
to any unnecessary component?
J9507-61
7 - 26 COOLING SYSTEM — — — BR
Condition Possible Causes Correction

STEAM IS COMING FROM 1. During wet weather, moisture 1. Occasional steam emitting from this
FRONT OF VEHICLE NEAR (snow,' ice or rain condensation) area is normal. No repair is necessary.
GRILL AREA WHEN on the radiator will evaporate
WEATHER IS WET, ENGINE when the thermostat opens.
IS WARMED UP AND This opening allows heated
RUNNING, AND VEHICLE IS water into the radiator. When
STATIONARY. the moisture contacts the hot
TEMPERATURE GAUGE IS radiator, steam may be emitted.
IN NORMAL RANGE This usually occurs In cold
weather with no fan or airflow
to blow it away.
COOLANT COLOR 1. Coolant color is not necessarily 1. Refer to Coolant in this group for
an indication of adequate antifreeze tests. Adjust antifreeze-to-
corrosion or temperature water ratio as necessary.
protection. Do not rely on
coolant color for determining
condition of coolant.
COOLANT LEVEL CHANGES 1. Level changes are to be 1. A normal condition. No repair is
IN COOLANT RESERVE/ expected as coolant volume necessary.
OVERFLOW TANK. fluctuates with engine
TEMPERATURE GAUGE temperature. If the level in the
IS IN NORMAL RANGE tank was between the FULL
and ADD marks at normal
engine operating temperature,
the level should return to
within that range after operation
at elevated temperatures.
J9507-55
DIAGNOSIS AND T E S T I N G ( C o n t i n u e d )
RADIATOR COOLANT FLOW TEST

Use the following procedure to determine i f coolant
is flowing through the cooling system,
(1) Idle engine until operating temperature is
reached. I f the upper radiator hose is warm to the
touch, the thermostat is opening and coolant is flow
ing to the radiator.
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. USING A RAG TO
COVER THE RADIATOR PRESSURE CAP, OPEN
RADIATOR CAP SLOWLY TO THE FIRST STOP. THIS
WILL ALLOW ANY BUILT-UP PRESSURE TO VENT
TO THE RESERVE/OVERFLOW TANK. AFTER PRES
SURE BUILD-UP HAS BEEN RELEASED, REMOVE
CAP FROM FILLER NECK.
Fig. 32 Pressure Testing Cooling System—Typical
(2) Drain a small amount of coolant from the radi
not be detected, inspect for interior leakage or per
ator until the ends of the radiator tubes are visible
form Internal Leakage Test.
through the filler neck. Idle the engine at normal
Drops Slowly: Indicates a small leak or seepage
operating temperature. I f coolant is flowing past the
is occurring. Examine all connections for seepage or
exposed tubes, the coolant is circulating.
slight leakage with a flashlight. Inspect radiator,
hoses, gasket edges and heater. Seal small leak holes
TESTING COOLING SYSTEM FOR LEAKS
with a sealer lubricant (or equivalent). Repair leak
PRESSURE TESTER METHOD holes and inspect system again with . pressure
The engine should be at normal operating temper applied.
ature. Recheck the system cold i f cause of coolant Drops Quickly: Indicates that serious leakage is
loss is not located during the warm engine examina occurring. Examine system for external leakage. I f
tion. leaks are not visible, inspect for internal leakage.
Large radiator leak holes should be repaired by a
WARNING: HOT, PRESSURIZED COOLANT CAN reputable radiator repair shop.
CAUSE INJURY BY SCALDING.
ULTRAVIOLET LIGHT METHOD
Carefully remove radiator pressure cap from filler A leak detection additive is available through the
neck and check coolant level. Push down on cap to parts department that can be added to cooling sys
disengage it from stop tabs. Wipe inside of filler neck tem. The additive is highly visible under ultraviolet
and examine lower inside sealing seat for nicks, light (black light). Pour one ounce of additive into
cracks, paint, dirt and solder residue. Inspect radia- cooling system. Place heater control unit i n HEAT
tor-to- reserve/overflow tank hose for internal position. Start and operate engine until radiator
obstructions. Insert a wire through the hose to be upper hose is warm to touch. Aim the commercially
sure i t is not obstructed. available black light tool at components to be
Inspect cams on outside of filler neck. I f cams are checked. I f leaks are present, black light will cause
bent, seating of pressure cap valve and tester seal additive to glow a bright green color.
will be affected. Replace cap i f cams are bent. The black light can be used in conjunction with a
Attach pressure tester (7700 or an equivalent) to pressure tester to determine i f any external leaks
radiator filler neck (Fig. 32). exist (Fig. 33).
Operate tester pump to apply 103.4 kPa (15 psi)
pressure to system. I f hoses enlarge excessively or INTERNAL LEAKAGE TEST
bulges while testing, replace as necessary. Observe Remove engine oil pan drain plug and drain a
gauge pointer and determine condition of cooling sys small amount of engine oil. I f coolant is present in
tem according to following criteria: the pan, it will drain first because it is heavier than
Holds Steady: I f pointer remains steady for two oil. An alternative method is to operate engine for a
minutes, serious coolant leaks are not present i n sys short period to churn the oil. After this is done,
tem. However, there could be an internal leak that remove engine dipstick and inspect for water glob
does not appear with normal system test pressure. I f ules. Also inspect transmission dipstick for water
it is certain that coolant is being lost and leaks can- globules and transmission fluid cooler for leakage.
able Block Leak Check tool. Follow manufacturers
instructions when using this product.
COMBUSTION LEAKAGE TEST—WITHOUT

PRESSURE TESTER
DO NOT WASTE reusable coolant. I f solution is
clean, drain coolant into a clean container for reuse.
WARNING: DO NOT REMOVE CYLINDER B L O C K

DRAIN P L U G S OR L O O S E N RADIATOR DRAIN-
C O C K WITH S Y S T E M HOT AND UNDER P R E S S U R E .
SERIOUS BURNS FROM COOLANT CAN OCCUR.
Drain sufficient coolant to allow thermostat

removal. Refer to Thermostat Replacement. Discon
nect water pump drive belt.
Add coolant to radiator to bring level to within 6.3
mm (1/4 in) of top of thermostat housing.
CAUTION: Avoid overheating. Do not operate

engine for an excessive period of time. Open drain-
cock immediately after test to eliminate boil over.
Fig, 88 Leak Detection Using Black Light—Typical Start engine and accelerate rapidly three times, to
WARNING: WITH COOLING SYSTEM PRESSURE approximately 3000 rpm (2000 rpm for diesel) while
T E S T E R TOOL INSTALLED ON RADIATOR, DO NOT
observing coolant. I f internal engine combustion
ALLOW P R E S S U R E TO E X C E E D 110 KPA (20 PSI).
gases are leaking into cooling system, bubbles will
P R E S S U R E WILL BUILD UP QUICKLY IF A COM
appear in coolant. I f bubbles do not appear, internal
BUSTION LEAK IS PRESENT. TO R E L E A S E P R E S
combustion gas leakage is not present.
S U R E , ROCK T E S T E R FROM SIDE TO SIDE. WHEN
REMOVING T E S T E R , DO NOT TURN T E S T E R MORE VISCOUS FAN DRIVE
THAN 1/2 TURN IF SYSTEM IS UNDER P R E S S U R E .
NOISE
Operate engine without pressure cap on radiator
NOTE: It is normal for fan noise to be louder (roar
until thermostat opens. Attach a pressure tester to
ing) when:
filler neck. I f pressure builds up quickly it indicates a
combustion leak exists. This is usually the result of a • The underhood temperature is above the engage
cylinder head gasket leak or crack in engine. Repair ment point for the viscous drive coupling. This may
as necessary. occur when ambient (outside air temperature) is very
If there is not an immediate pressure increase, high.
pump the pressure tester. Do this until indicated • Engine loads and temperatures are high such as
pressure is within system range of 110 kPa (16 psi). when towing a trailer.
Fluctuation of gauge pointer indicates compression or • Cool silicone fluid within the fan drive unit is
combustion leakage into cooling system. being redistributed back to its normal disengaged
Because the vehicle is equipped with a catalytic (warm) position. This can occur during the first 15
converter, do not remove spark plug cables or short seconds to one minute after engine start-up on a cold
out cylinders (non-diesel engines) to isolate compres engine.
sion leak.
If the needle on dial of pressure tester does not LEAKS
fluctuate, race engine a few times to check for an Viscous fan drive operation is not affected by small
abnormal amount of coolant or steam. This would be oil stains near the drive bearing. I f leakage appears
emitting from exhaust pipe. Coolant or steam from excessive, replace the fan drive unit.
exhaust pipe may indicate a faulty cylinder head gas
ket, cracked engine cylinder block or cylinder head. TESTING
A convenient check for exhaust gas leakage into If the fan assembly free-wheels without drag (the
cooling system is provided by a commercially avail fan blades will revolve more than five turns when
DIAGNOSIS AND TESTING { C o n t i n u e d )

spun by hand), replace the fan drive. This spin test CAUTION: If the viscous fan drive Is replaced
must be performed when the engine is cool. because of mechanical . damage, the cooling fan
For the following test, the cooling system must be blades should also be inspected. Inspect for fatigue
in good condition. I t also will ensure against exces cracks, loose blades, or loose rivets that could
sively high coolant temperature. have resulted from excessive vibration. Replace fan
blade assembly if any of these conditions are
WARNING; BE SURE THAT THERE IS ADEQUATE found. Also inspect water pump bearing and shaft
FAN BLADE CLEARANCE BEFORE DRILLING. assembly for any related damage due to a viscous
fan drive malfunction.
(1) Drill a 3.18-mm (1/8-in) diameter hole i n the
top center of the fan shroud.
(2) Obtain a dial thermometer with an 8 inch stem SERPENTINE DRIVE BELT DIAGNOSIS—ALL
(or equivalent). I t should have a range of -18°-to- ENGINES
1 0 5 ° C (0°-to-220° F). Insert thermometer through the
When diagnosing serpentine drive belts, small
hole i n the shroud. Be sure that there is adequate cracks that run across ribbed surface of belt from rib
clearance from the fan blades. to rib (Fig. 3 4 ) , are considered normal. These are not
(3) Connect a tachometer and an engine ignition a reason to replace belt. However, cracks running
timing light. The timing light is to be used as a along a rib (not across) are not normal. Any belt
strobe light. This step cannot be used on the diesel with cracks running along a rib must be replaced
engine. (Fig. 3 4 ) . Also replace belt i f i t has excessive wear,
(4) Block the air flow through the radiator. Secure frayed cords or severe glazing.
a sheet of plastic in front of the radiator (or air con Refer to the Serpentine Drive Belt Diagnosis chart
ditioner condenser). Use tape at the top to secure the for further belt diagnosis. Also refer to Automatic
plastic and be sure that the air flow is blocked. Belt Tensioner proceeding in this group.
(5) Be sure that the air conditioner (if equipped) is
turned off.
WARNING: USE EXTREME CAUTION WHEN THE

ENGINE IS OPERATING- DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
NORMAL CRACKS
BELT OK
(6) Start the engine and operate at 2 4 0 0 rpm.
Within ten minutes the air temperature (indicated on
the dial thermometer) should be up to 8 8 ° C ( 1 9 0 ° F).
Fan drive engagement should have started to occur
at between 7 4 ° to 8 2 ° C ( 1 6 5 ° to 1 8 0 ° F). Engage
ment is distinguishable by a definite increase i n fan
flow noise (roaring). The timing light also will indi
cate an increase i n the speed of the fan (non-diesel
only).
( 7 ) When the air temperature reaches 8 8 ° C ( 1 9 0 °
F), remove the plastic sheet. Fan drive disengage
ment should have started to occur at between 5 7 ° to NOT NORMAL CRACKS
REPLACE BELT J9007-44
7 9 ° C ( 1 3 5 ° to 1 7 5 ° F). A definite decrease of fan
flow noise (roaring) should be noticed. I f not, replace * Fig. 34 Serpentine Accessory Drive Beit Wear
the defective viscous fan drive unit. Patterns
CAUTION: Some engines equipped with serpentine

drive belts have reverse rotating fans and viscous
fan drives. They are marked with the word
REVERSE to designate their usage. Installation of
the wrong fan or viscous fan drive can result in
engine overheating.
7 - 30 COOLING SYSTEM _ _ _ _ _ — _ — - — BR

SERPENTINE DRIVE BELT DIAGNOSIS

RIB CHUNKING (ONE 1. Foreign objects imbedded in 1. Remove foreign objects from pulley
OR MORE RIBS HAS pulley grooves. grooves. Replace belt.
SEPARATED FROM 2. Installation damage. 2. Replace belt.
BELT BODY
RIB OR BELT WEAR 1. Pulley(s) misaligned. 1. Align pulley(s).

2. Abrasive environment. 2. Clean pulley(s). Replace belt if necessary.
3. Rusted pulley(s). 3. Clean rust from pulley(s).
4. Sharp or jagged pulley 4. Replace pulley.
groove tips.
5. Rubber deteriorated. 5. Replace belt.
LONGITUDINAL BELT 1. Belt has mistracked from 1. Replace belt.

CRACKING (CRACKS pulley groove.
BETWEEN TWO RIBS) 2. Pulley groove tip has worn 2. Replace belt.
away rubber to tensile
member.
BELT SLIPS 1. Belt slipping because of 1. Replace automatic belt tensioner.

insufficient tension.
2. Incorrect belt. 2. Replace belt.
3. Belt or pulley subjected to 3. Replace belt and clean pulleys.
substance (belt dressing, oil,
ethylene glycol) that has
reduced friction.
4. Driven component bearing 4. Replace fauity component bearing.
failure.
5. Belt glazed and hardened 5. Replace belt.
from heat and excessive
slippage.
"GROOVE JUMPING" 1. Belt tension either too high or 1. Replace automatic belt tensioner.
(BELT DOES NOT too low.
MAINTAIN CORRECT 2. Incorrect belt. 2. Replace belt.
POSITION ON PULLEY)
3. Pulley(s) not within design 3. Replace pulley(s).
tolerance.
4. Foreign object(s) in grooves. 4. Remove foreign objects from grooves.
4. Pulley misalignment. 4. Check and replace.
5. Belt cordline is broken. 5. Replace belt.
BELT BROKEN 1. Excessive tension, 1. Replace belt and automatic belt tensioner.
(NOTE: IDENTIFY AND 2. Incorrect belt. 2. Replace belt.
CORRECT PROBLEM
3. Tensile member damaged 3. Replace belt.
BEFORE NEW BELT
during belt installation.
IS INSTALLED)
4. Severe misalignment. 4. Check and replace.
5. Bracket, pulley, or bearing 5. Replace defective component and belt.
failure.
NOISE (OBJECTIONAL 1. Belt slippage. 1. Replace belt or automatic belt tensioner.

SQUEAL, SQUEAK, OR 2. Bearing noise. 2. Locate and repair.
RUMBLE IS HEARD OR
3. Belt misalignment. 3. Replace belt. j
FELT WHILE DRIVE
BELT IS IN OPERATION) 4. Belt-to-pulley mismatch. 4. Install correct belt. |
J9507-27
THERMOSTAT—DIESEL (3) Place the thermostat into a container filled

The cooling system used with the diesel engine with water.
provides the extra coolant capacity and extra cooling (4) Place the container on a hot plate or other suit
protection needed for higher GVWR (Gross Vehicle able heating device.
Weight Rating) and GCWR (Gross Combined Weight (5) Place a commercially available radiator ther
Rating) vehicles. mometer into the water.
This system capacity will not effect warm up or (6) Apply heat to the water while observing the
cold weather operating characteristics i f the thermo thermostat and thermometer.
stat is operating properly. This is because coolant (7) When the water temperature reaches 83°C
will be held i n the engine until i t reaches the ther (181°F) the thermostat should start to open (valve
mostat "set" temperature. will start to move). I f the valve starts to move before
Diesel engines, due to their inherent efficiency are this temperature is reached, i t is opening too early.
slower to warm up than gasoline powered engines, Replace thermostat. The thermostat should be fully
and will operate at lower temperatures when the open (valve will stop moving) at 95°C (203°F).
vehicle is unloaded. Because of this, lower tempera (8) I f the valve is still moving when the water tem
ture gauge readings for diesel versus gasoline perature reaches 203°, i t is opening too late. Replace
engines may, at times be normal. thermostat.
Typically, complaints of low engine coolant temper (9) I f the valve refuses to move at any time,
ature are observed as low heater output when com replace thermostat.
bined with cool or cold outside temperatures.
To help promote faster engine warm-up, the elec THERMOSTAT—GAS ENGINES
tric engine block heater must be used with cool or
cold outside temperatures. This will help keep the ON-BOARD DIAGNOSTICS
engine coolant warm when the vehicle is parked. Use All gasoline powered models are equipped with
the block heater i f the outside temperature is below On-Board Diagnostics for certain cooling system com
4°C (40°F). Do not use the Mock heater i f the ponents. Refer to On-Board Diagnostics (OBD) i n the
outside temperature is above 4°C (40°F). Diagnosis section of this group for additional infor
A "Cold Weather Cover" is available from the parts mation. I f the powertrain control module (PCM)
department through the Mopar Accessories product detects low engine coolant temperature, i t will record
line. This accessory cover is designed to block airflow a Diagnostic Trouble Code (DTC) in the PCM mem
ory. The DTC number for low coolant temperature is
entering the radiator and engine compartment to
17. Do not change a thermostat for lack of heat as
promote faster engine warm-up. I t attaches to the
indicated by the instrument panel gauge or by poor
front of the vehicle at the grill opening. The cover is
heater performance unless a DTC number 17 is
to be used with cool or cold temperatures only.
present. Refer to the Diagnosis section of this group
I f used with high outside temperatures, serious
for other probable causes. For other DTC numbers,
engine damage could result. Refer to the litera
refer to On-Board Diagnostics in the General Diagno
ture supplied with the cover for additional informa
sis section of Group 14, Fuel Systems.
tion.
TESTING NOTE: Vehicles equipped with a 5.9L diesel engine

The following test procedure is to be used for the do not have the DTC number 17 check engine lamp
diesel engine only. feature.
NOTE: The DRB scan tool cannot be used to mon The DTC can also be accessed through the DRB
itor engine coolant temperature on the diesel scan tool. Refer to the appropriate Powertrain Diag
engine. nostic Procedures manual for diagnostic information
and operation of the DRB scan tool.
(1) To determine i f the thermostat is defective, i t
must be removed from the vehicle. Refer to Thermo WATER PUMP
stats for removal and installation procedures. A quick test to determine i f pump is working is to
(2) After the thermostat has been removed, exam check i f heater warms properly. A defective water
ine the thermostat and inside of thermostat housing pump will not be able to circulate heated coolant
for contaminants. I f contaminants are found, the through the long heater hose to the heater core.
thermostat may already be i n a "stuck open" position.
Flush the cooling system before replacing thermostat.
Refer to Cooling System Cleaning/Reverse Flushing
in this group for additional information.
RADIATOR CAP-TO-FILLER NECK S E A L -

PRESSURE RELIEF CHECK
The pressure cap upper gasket (seal) pressure
relief can be tested by removing overflow hose from
radiator filler neck nipple. Attach hose of pressure
tester tool 7700 (or equivalent) to nipple. I t will be
necessary to disconnect hose from its adapter for
filler neck. Pump air into radiator. The pressure cap
upper gasket should relieve at 69-124 kPa (10-18 psi)
and hold pressure at a minimum of 55 kPa (8 psi).
WARNING: THE WARNING WORDS —DO NOT
OPEN HOT— ON RADIATOR PRESSURE CAP, ARE
A SAFETY PRECAUTION. WHEN HOT, PRESSURE
BUILDS UP IN COOLING SYSTEM. TO PREVENT
SCALDING OR INJURY, RADIATOR CAP SHOULD
NOT BE REMOVED WHILE SYSTEM IS HOT AND/OR
UNDER PRESSURE.
Do not remove radiator cap at any time except for

the following purposes: J9507-3
• Check and adjust antifreeze freeze point

• Refill system with new antifreeze Fig. 35 Pressure Testing Radiator Cap—Typical
• Conducting service procedures Tester
• Checking for vacuum leaks damage. Also inspect for dirt or distortion that may
prevent cap from sealing properly.
WARNING: IF VEHICLE HAS BEEN RUN
RECENTLY, WAIT AT LEAST 15 MINUTES BEFORE CAUTION: Radiator pressure testing tools are very
REMOVING RADIATOR CAP. WITH A RAG, sensitive to small air leaks, which will not cause
SQUEEZE RADIATOR UPPER HOSE TO CHECK IF cooling system problems. A pressure cap that does
SYSTEM IS UNDER PRESSURE. PLACE A RAG not have a history of coolant loss should not be
OVER CAP AND WITHOUT PUSHING CAP DOWN, replaced just because it leaks slowly when tested
ROTATE IT COUNTER-CLOCKWISE TO FIRST STOP. with this tool. Add water to tool. Turn tool upside
ALLOW FLUID TO ESCAPE THROUGH THE COOL down and recheck pressure cap to confirm that cap
ANT RESERVE/OVERFLOW HOSE INTO RESERVE/ needs replacement.
OVERFLOW TANK. SQUEEZE RADIATOR UPPER
HOSE TO DETERMINE WHEN PRESSURE HAS
BEEN RELEASED. WHEN COOLANT AND STEAM LOW COOLANT LEVEL—AERATION
STOP BEING PUSHED INTO TANK AND SYSTEM I f the coolant level in the radiator drops below the
PRESSURE DROPS, REMOVE RADIATOR CAP top of the radiator core tubes, air will enter the sys
COMPLETELY. tem.
Low coolant level can cause the thermostat pellet
to be suspended i n air instead of coolant. This will
PRESSURE TESTING RADIATOR CAPS cause the thermostat to open later, which in turn
Remove cap from radiator. Be sure that sealing causes higher coolant temperature. Air trapped in
surfaces are clean. Moisten rubber gasket with water cooling system also reduces the amount of coolant
and install cap on pressure tester 7700 or an equiv circulating in the heater core. This may result in low
alent (Fig. 35). heat output.
Operate tester pump to bring pressure to 104 kPa
(15 psi) on gauge. I f pressure cap fails to hold pres iEAERATION
sure of at least 97 kPa (14 psi) replace cap. Refer to As the engine operates, air trapped in the cooling
CAUTION below. system gathers under the radiator cap. The next time
The pressure cap may test properly while posi engine is operated, thermal expansion of coolant will
tioned on tool 7700 (or equivalent). I t may not hold push trapped air past radiator cap into coolant
pressure or vacuum when installed on radiator. I f so, reserve/overflow tank. Here it escapes to atmosphere
inspect radiator filler neck and cap's top gasket for in the tank. When engine cools down the coolant, it
will be drawn from reserve/overflow tank into radia and coolant reserve/overflow system connection.
tor to replace removed air. Remove radiator cap. The coolant level should be to
the top of the radiator. I f not and i f coolant level in
re serve/overflow tank is at the ADD mark, check for:
SERVICE PROCEDURES • An air leak in the coolant reserve/overflow tank
• An air leak in the radiator filler neck
COOLANT LEVEL CHECK—ROUTINE ® Leak in the pressure cap seal to the radiator
filler neck
NOTE: Do not remove radiator cap for routine
coolant level inspections. The coolant level can be
DRAINING COOLING SYSTEM
checked at the coolant reserve/overflow tank.
WARNING: DO NOT REMOVE THE CYLINDER
The coolant reserve/overflow system provides a
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
quick visual method for determining the coolant level
DRAIN PLUG WITH SYSTEM HOT AND UNDER
without removing the radiator pressure cap. With
PRESSURE. SERIOUS BURNS FROM COOLANT
engine idling and at normal operating temperature,
CAN OCCUR.
observe coolant level in coolant reserve/overflow
tank. The coolant level should be between the ADD DO NOT WASTE reusable coolant. I f the solution
and FULL marks. is clean, drain the coolant into a clean container for
reuse.
COOLANT SERVICE—V-6, V-8, AND V-10 ENGINES (1) Start the engine and place the heater control
It is recommended that the cooling system be temperature selector in the Full-On position. Engine
drained and flushed at 84,000 kilometers (52,500 vacuum is needed to actuate the heater controls.
miles) or 3 years, whichever occurs first. Then every (2) Turn the ignition off.
two years or 48,000 kilometers (30,000 miles), which (3) Do not remove radiator cap when draining cool
ever occurs first. ant from reserve/overflow tank. Open radiator drain
plug and when tank is empty, remove radiator cap. I f
COOLANT SERVICE—DIESEL ENGINE the coolant reserve/overflow tank does not drain,
It is recommended that the cooling system be refer to the Testing Cooling System for Leaks section
drained and flushed every 24 months or 38,600 kilo in this group. The coolant need not be removed from
meters (24,000 miles), whichever occurs first. tank unless the system is being refilled with fresh
mixture.
ADDING ADDITIONAL COOLANT—ROUTINE (4) On vehicles equipped with gas powered
Do not remove the radiator cap to add cool engines, remove the cylinder block drain plugs. These
ant to the system. When adding coolant to main are located on the sides of the block just above the oil
tain the correct level, do so at the coolant reserve/ pan (Fig. 36).
overflow tank with a 50/50 mixture of ethylene glycol (5) Remove radiator pressure cap.
antifreeze (containing Alugard 340-2 ®) and water.
Remove the radiator cap only for testing or when
refilling the system after service. Removing cap
unnecessarily can cause loss of coolant and allow air
to enter system. This produces corrosion.
COOLANT LEVEL C H E C K — S E R V I C E
The cooling system is closed and designed to main
tain coolant level to the top of the radiator.
WARNING: DO NOT OPEN RADIATOR DRAINCOCK

WITH ENGINE RUNNING OR WHILE ENGINE IS HOT
AND COOLING SYSTEM IS UNDER PRESSURE.
When vehicle servicing requires a coolant level

check in the radiator, drain several ounces of coolant
from the radiator drain cock. Do this while observing
the coolant reserve/overflow system tank. The coolant
level in the reserve/overflow tank should drop
slightly. I f not, inspect for a leak between radiator Fig. 36 Drain Plugs—Gas Powered Engines—Typical
7 - 34 COOLING SYSTEM -
REFILLING COOLING SYSTEM refill between blasts. Continue this reverse flushing
Clean cooling system prior to refilling. Refer to until clean water flows out through rear of radiator
Cooling System Cleaning section of this group. cooling tube passages. Have radiator cleaned more
(1) Install the cylinder block drain plugs (Fig. 36). extensively by a radiator repair shop.
(2) Close radiator drain plug.
(3) Fill the cooling system with a 50/50 mixture of REVERSE FLUSHING ENGINE-VS V-8S AND
water and antifreeze. 5.9L Diesel Engine Only; The V-10
diesel engine is equipped with a one-way check valve Drain cooling system. Remove thermostat housing
(jiggle pin). The check valve is used as a servicing and thermostat. Install thermostat housing. Discon
feature and will vent air when the system is being nect radiator upper hose from radiator and attach
filled. Water pressure (or flow) will hold the valve flushing gun to hose. Disconnect radiator lower hose
closed. Due to the use of this valve, the engine from water pump and attach a lead-away hose to
must not be operating when r e f i l l i n g the cool water pump inlet fitting.
ing system. Refer to Thermostat Operation—5.9L Connect water supply hose and air supply hose to
Diesel Engine in the Thermostat section of this group flushing gun. Allow engine to fill with water. When
for more information. engine is filled, apply air in short blasts, allowing
(4) Fill coolant reserve/overflow tank to the FULL system to fill between air blasts. Continue until clean
mark. water flows through the lead away hose.
(5) Start and operate engine until thermostat Remove lead away hose, flushing gun, water sup
opens. Upper radiator hose should be warm to touch. ply hose and air supply hose. Remove thermostat
(6) I f necessary, add 50/50 water and antifreeze housing and install thermostat. Install thermostat
mixture to the coolant reserve/overflow tank to main housing with a replacement gasket. Refer to Thermo
tain coolant level. This level should be between the stat Replacement. Connect radiator hoses. Refill cool
ADD and FULL marks. The level in the reserve/over ing system with correct antifreeze/water mixture.
flow tank may drop below the ADD mark after three Refer to Refilling the Cooling System.
or four warm-up and cool-down cycles.
REVERSE FLUSHING ENGINE—DIESEL
(1) Drain the cooling system.
COOLING SYSTEM CLEANING/REVERSE FLUSHING
(2) Disconnect the upper hose from the radiator.
CLEANING (3) Disconnect the radiator lower hose from the
Drain cooling system and refill with water. Run water pump.
engine with radiator cap installed until upper radia (4) Remove the heater core inlet hose from tube
tor hose is hot. Stop engine and drain water from (Fig. 37).
system. I f water is dirty, fill system with water, run
engine and drain system. Repeat until water drains
clean.
REVERSE FLUSHING
Reverse flushing of cooling system is the forcing of
water through the cooling system. This is done using
air pressure in the opposite direction of normal cool
ant flow. I t is usually only necessary with very dirty
systems with evidence of partial plugging.
REVERSE FLUSHING RADIATOR

Disconnect radiator hoses from radiator inlet and
outlet. Attach a section of radiator hose to radiator
bottom outlet fitting and insert flushing gun. Con
nect a water supply hose and air supply hose to
flushing gun.
Fig. 37 Typical Reverse-flushing—5.9L Diesel
CAUTION: Internal radiator pressure must not (5) Attach water supply hose to heater tube.
exceed 138 kPa (20 psi) as damage to radiator may (6) Back-flush the engine until clean water exits
result. the water pump inlet.
Allow radiator to fill with water. When radiator is

filled, apply air in short blasts. Allow radiator to
CHEMICAL CLEANING COOLANT
In some instances, use a radiator cleaner (Mopar RESERVE/OVERFLOW
Radiator Kleen or equivalent) before flushing. This
will soften scale and other deposits and aid flushing
operation.
CAUTION: Follow manufacturers instructions when

using these products.
COOLANT RESERVE/OVERFLOW TANK
TANK REMOVAL—ALL EXCEPT 8.0L V-10 BOLTS (2) J948D-21

ENGINE
(1) Remove overflow hose from radiator. Fig. 89 COOLANT RESERVE/OVERFLOW TANK—V-
(2) Unsnap the coolant reserve/overflow tank from 10 ENGINE
fan shroud. Lift straight up. The fan shroud is INSTALLATION
equipped with T-shaped slots (Fig. 38) to attach the (1) Position tank to inner fender.
tank. An alignment pin is located on the side of tank. (2) Install bolts and tighten to 6 N-m (50 in. lbs.)
torque.
INSTALLATION
(3) Connect overflow hose to radiator.
(1) Snap the tank into the two T-slots and the
alignment pin on fan shroud. WATER PUMP—V-6 AND V-8 ENGINES
(2) Connect overflow hose to radiator.
REMOVAL
The water pump on all models can be removed
without discharging the air conditioning system (if
equipped).
The water pump on all gas powered engines is
bolted directly to the engine timing chain case/cover.
On all 3.9L/5.2L/5.9L gas powered engines, a gas
ket is used as a seal between the water pump and
timing chain case/cover.
If water pump is replaced because of bearing/shaft
damage or leaking shaft seal, the mechanical cooling
fan assembly should also be inspected. Inspect for
fatigue cracks, loose blades or loose rivets that could
have resulted from excessive vibration. Replace fan i f
any of these conditions are found. Also check condi
tion of the thermal viscous fan drive. Refer to Viscous
Fan Drive in this group.
(1) Disconnect negative battery cable from battery.
(2) Drain cooling system. Refer to Draining Cool
ing System in this group.
Do not waste reusable coolant. I f solution is clean,
drain coolant into a clean container for reuse.
Fig. 38 COOLANT RESERVE/OVERFLOW TANK- (3) Remove windshield washer reservoir tank from
ALL EXCEPT 8.0L V-10 ENGINE radiator fan shroud. Refer to Group 8K, Windshield
TANK REMOVAL—8.0L V-10 ENGINE Wiper and Washer Systems.
(1) Remove overflow hose from radiator. (4) Disconnect the coolant reserve/overflow tank-
(2) Remove three tank mounting bolts (Fig. 39) to-radiator hose at the tank.
and remove tank. (5) Remove the four fan shroud mounting bolts at
the radiator (Fig. 40). Do not attempt to remove
shroud from vehicle at this time.

RADIATOR fluid in the viscous drive could drain into its bearing
assembly and contaminate the bearing lubricant.
(11) Do not remove the water pump pulley bolts
FAN
at this time.
SHROUD
ASSEMBLY PUMP
PULLEY
BYPASS
THREADED HOSE
NUT
FAN SHROUD M O U N T I N G BOLTS J9407-37
THREADED SHAFT CRANKSHAFT

Fig. 40 Typical Fan Shroud Mounting (WATER PUMP HUB) PULLEY
WARNING: CONSTANT TENSION HOSE CLAMPS
VISCOUS FAN DRIVE
ARE USED ON MOST COOLING SYSTEM HOSES. J9307-32
WHEN REMOVING OR INSTALLING, USE ONLY Fig. 41 Fan Blade and Viscous Fan Drive—Typical
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER (12) Remove accessory drive belt as follows: The
6094) (Fig. 23). SNAP-ON CLAMP TOOL (NUMBER drive belt is equipped with a spring loaded automatic
HPC-20) MAY BE USED FOR LARGER CLAMPS. tensioner (Fig. 42) (Fig. 43).
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC
ING CONSTANT TENSION CLAMPS.

tongue of constant tension clamps. (Fig. 24). If
(6) Remove upper radiator hose at radiator.

(7) The thermal viscous fan drive is attached (threaded)
to the water pump hub shaft (Fig. 41). Remove the fan/fan
drive assembly from water pump by turning the mounting
nut counterclockwise (as viewed from front). Threads on
the fan drive are RIGHT-HAND. A Snap-On 36 M M
Fan Wrench (number SP346 from Snap-On Cummins
Diesel Tool Set number 2017DSP) can be used. Place
a bar or screwdriver between the water pump pulley
bolts (Fig. 41) to prevent the pulley from rotating.
(8) I f water pump is being replaced, do not unbolt
fan blade assembly (Fig. 41) from the thermal control
J9219-15
fan drive.
(9) Remove fan blade/fan drive and fan shroud as Fig. 42 Belt Tensioner—3.9L V-6 or 5.2/5.9L V-8
an assembly from vehicle. LDC-Gas Engines
(10) After removing fan blade/fan drive assembly, (13) 3.9L V-6 or 5.2/5.9L V-8 LDC-Gas Engines:
do not place the thermal viscous fan drive in the Relax the tension from the belt by rotating the ten-
horizontal position. I f stored horizontally, the silicone
BR — — ^ ^— « • COOLING SYSTEM 7 - 37

sioner clockwise (as viewed from front) (Fig. 42).
When all belt tension has been relaxed, remove
accessory drive belt.
(14) 5.9L HDC-Gas Engine: Relax the tension from
the belt by rotating the tensioner counterclockwise
(as viewed from front) (Fig. 43). When all belt ten
sion has been relaxed, remove accessory drive belt.
Fig. 44 Coolant Return Tube—3.9L V-6 or 5.2/5.9L

V-8 LDC-Gas Engines
Fig. 43 Beit Tensioner—5.9L HDC-Gas Engine

(15) Remove the four water pump pulley-to-water
pump hub bolts (Fig. 41) and remove pulley from
vehicle,
(16) Remove the lower radiator hose and heater
hose from water pump.
(17) Loosen heater hose coolant return tube
mounting bolt (Fig. 44) (Fig. 45)and remove tube
from water pump. Discard the old tube O-ring.
(18) Remove the seven water pump mounting bolts
(Fig. 46).
(19) Loosen the clamp at the water pump end of
bypass hose (Fig. 41). Slip the bypass hose from the
water pump while removing pump from vehicle. Do
not remove the clamp from the bypass hose.
(20) Discard old gasket.
CAUTION: Do not pry the water pump at timing Fig. 45 Coolant Return Tube—5.9L HDC-Gas Engine
chain case/cover. The machined surfaces may be pump bolts (Fig. 46). Tighten water pump mounting
damaged resulting in leaks. bolts to 40 N-m (30 ft. lbs.) torque.
(3) Position bypass hose clamp to bypass hose.
INSTALLATION (4) Spin water pump to be sure that pump impel
(1) Clean gasket mating surfaces. ler does not rub against timing chain case/cover.
(2) Using a new gasket, install water pump to (5) Install a new o-ring to the heater hose coolant
engine as follows: Guide water pump nipple into return tube (Fig. 44) (Fig. 45). Coat the new o-ring
bypass hose as pump is being installed. Install water with antifreeze before installation.
R E M O V A L AMB I N S T A L L A T I O N ( C o n t i n u e d )
Fig. 46 Water Pump Bolts—3.9L V-8 or 5.2/5.9L V-8

Gas Engines—Typical
(6) Install coolant return tube and its mounting
bolt to engine (Fig, 44) (Fig. 45). Be sure the slot in *IF VEHICLE IS NOT EQUIPPED WITH POWER
tube bracket is bottomed to mounting bolt. This will STEERING, THIS WILL BE A N IDLER PULLEY. J9307-26
properly position return tube.

Fig. 47 Belt Routing—3.9L V-6 or 5.2/5.9L V-8
(7) Connect radiator lower hose to water pump. :
LDC-Gas Engines
(8) Connect heater hose and hose clamp to coolant
return tube. AUTOMATIC
(9) Install water pump pulley. Tighten bolts to 27 TENSIONER
N-m (20 ft. lbs.) torque. Place a bar or screwdriver
between water pump pulley bolts (Fig. 41) to prevent
pulley from rotating.
(10) Relax tension from automatic belt tensioner
(Fig. 42) (Fig. 43). Install drive belt.
CAUTION: When installing the serpentine acces

sory drive belt, the belt must be routed correctly. If
not, engine may overheat due to water pump rotat
ing in w r o n g direction. Refer to (Fig. 47) (Fig. 48)
(Fig. 49) for correct belt routing. The correct belt
with correct length must be used.
(11) Position fan shroud and fan blade/viscous fan

drive assembly to vehicle as a complete unit.
(12) Install fan shroud..
(13) Install fan blade/viscous fan drive assembly to
water pump shaft.
(14) Fill cooling system. Refer to Refilling Cooling J9307-55
System in this group.
(15) Connect negative battery cable. Fig. 48 Belt Routing—5.9L HDC-Gas Engine—With
(16) Start and warm the engine. Check for leaks. A/C
The water pump on all gas powered engines is
WATER PUMP—8.0L ¥-10 ENGINE bolted directly to the engine timing chain case/cover.
On the 8.0L V-10 engine, a rubber o-ring (instead
REMOVAL of a gasket) is used as a seal between the water
The water pump on all models can be removed pump and timing chain case/cover.
without discharging the air conditioning system (if I f water pump is replaced because of bearing/shaft
equipped). damage or leaking shaft seal, the mechanical cooling
fan assembly should also be inspected. Inspect for
AUTOMATIC RADIATOR
TENSIONER
FAN
SHROUD
J9307-56 FAN SHROUD M O U N T I N G BOLTS J9407-37
Fig, 49 Beit Routing—5.9L HDC-Gas Engine— Fig. 50 Typical Fan Shroud Mounting
Without A/C
(5) Remove upper radiator hose at radiator.
fatigue cracks, loose blades or loose rivets that could (6) The thermal viscous fan drive is attached
have resulted from excessive vibration. Replace fan i f (threaded) to the water pump hub shaft (Fig. 51).
any of these conditions are found. Also check condi Remove the fan/fan drive assembly from water pump
tion of the thermal viscous fan drive. Refer to Viscous by turning the mounting nut counterclockwise (as
Fan Drive in this group. viewed from front). Threads on the fan drive are
(1) Disconnect negative battery cable from battery. EIGHT-HAND, A Snap-On 36 M M Fan Wrench
(2) Drain cooling system. Refer to Draining Cool (number SP346 from Snap-On Cummins Diesel Tool
ing System in this group. Set number 2017DSP) can be used. Place a bar or
Do not waste reusable coolant. I f solution is clean, screwdriver between the water pump pulley bolts
drain coolant into a clean container for reuse. (Fig. 51) to prevent the pulley from rotating.
(3) Remove windshield washer reservoir tank from (7) I f water pump is being replaced, do not unbolt
radiator fan shroud. Refer to Group 8K, Windshield fan blade assembly (Fig. 51) from the thermal control
Wiper and Washer Systems. fan drive.
(4) Remove the four fan shroud mounting bolts at (8) Remove fan blade/fan drive and fan shroud as
the radiator (Fig. 50). Do not attempt to remove an assembly from vehicle.
shroud from vehicle at this time. After removing fan blade/fan drive assembly, do
not place the thermal viscous fan drive in the hori
WARNING: CONSTANT TENSION HOSE CLAMPS zontal position. I f stored horizontally, the silicone
ARE USED ON MOST COOLING SYSTEM HOSES. fluid in the viscous drive could drain into its bearing
WHEN REMOVING OR INSTALLING, USE ONLY assembly and contaminate the bearing lubricant.
Do not remove the water pump pulley bolts at this
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
time.
6094) (Fig. 23). SNAP-ON CLAMP TOOL (NUMBER
(9) Remove accessory drive belt as follows: The
HPC-20) MAY BE USED FOR LARGER CLAMPS.
drive belt is equipped with a spring loaded automatic
tensioner (Fig. 52).
Relax the tension from the belt by rotating the ten
sioner counterclockwise (as viewed from front) (Fig.
CAUTION: A number or letter is stamped into the 17). The threads on the pulley bolt are left-hand.
tongue of constant tension clamps (Fig. 24). If When all belt tension has been relaxed, remove
replacement is necessary, use only an original accessory drive belt.
R E M O V A L AMD fUSTALI (Continued)
F A N BLADE WATER WATER PUMP

ASSEMBLY D l | M C V PUMP
PULLEY PULLEY
THREADED ' BOLTS
NUT
THREADED SHAFT
(WATER PUMP HUB)
VISCOUS FAN DRIVE

J9307-32
Fig, 51 Fan Blade and Viscous Fan Drive—Typical Fig. 53 Water Pump Bolts—8.0L V-10—Typical
PULLEY
pump while removing pump from vehicle. Do not
BOLT remove the clamp from the bypass hose.
(15) Discard the water pump-to-timing chain/case
cover o-ring seal (Fig. 54).
TENSIONER
WATER PUMP
MOUNTING
BOLT
J9407-18
TENSIONER J9307-64 ,
Fig. 54 Water Pump O-Ring Seal—8.0L V-10
Fig. 52 Belt Tensioner—8.0L V-10 Engine (16) Remove the heater hose fitting from water
(10) Remove the four water pump pulley-to-water pump i f pump replacement is necessary. Note posi
pump hub bolts (Fig. 51) and remove pulley from tion (direction) of fitting before removal. Fitting must
vehicle. be re-installed to same position.
(11) Remove the lower radiator hose at water
pump. ION; Do not pry the water pump at timing
(12) Remove heater hose at water pump fitting. case/cover* The machined surfaces may be
(13) Remove the seven water pump mounting bolts damaged resulting in leaks.
(Fig. 53).
(14) Loosen the clamp at the water pump end of
bypass hose. Slip the bypass hose from the water

INSTALLATION (10) Relax tension from automatic belt tensioner
(1) I f water pump is being replaced, install the (Fig. 52). Install drive belt.
heater hose fitting to the pump. Tighten fitting to 16
N-m (144 in. lbs.) torque. After fitting has been CAUTION: When installing the serpentine acces
torqued, position fitting as shown in (Fig. 55). When sory drive belt, the belt must be routed correctly. If
positioning fitting, do not back off (rotate counter not, engine may overheat due to water pump rotat
clockwise). Use a sealant on the fitting such as ing in wrong direction. Refer to (Fig. 56) (Fig. 57)for
Mopar® Thread Sealant With Teflon. Refer to the correct belt routing. The correct belt with correct
directions on the package. length must be used.
CAUTION: This heater hose fitting must be installed AUTOMATIC

TENSIONER
to pump before pump is installed to engine.
HEATER
HOSE
FITTING
WATER
PUMP
<^ I FRONT
J9307-55
Fig. 56 Belt Routing—8.0L V-10 Engine—With A/C
J9407-17 AUTOMATIC
TENSIONER
Fig. 55 Heater Hose Fitting Position—8.0L V-10
(2) Clean the o-ring mating surfaces at rear of
water pump and front of timing chain/case cover.
(3) Apply a small amount of petroleum jelly to
o-ring (Fig. 54). This will help retain o-ring to water
pump.
(4) Install water pump to engine as follows: Guide
water pump fitting into bypass hose as pump is being
installed. Install water pump bolts (Fig. 53). Tighten
water pump mounting bolts to 40 N-m (30 ft. lbs.)
torque.
(5) Position bypass hose clamp to bypass hose.
(6) Spin water pump to be sure that pump impel
ler does not rub against timing chain case/cover.
(7) Connect radiator lower hose to water pump.
(8) Connect heater hose and hose clamp to heater
hose fitting.
(9) Install water pump pulley. Tighten bolts to 22
J9307-56
N-m (16 ft. lbs.) torque. Place a bar or screwdriver
between water pump pulley bolts (Fig. 51) to prevent Fig. 57 Belt Routing—8.0L V-10 Engine—Without
pulley from rotating. A/C
REMO' I N S T A L L A T I O N (Continued)
(12) Install fan shroud to radiator. Tighten bolts to O-RING
6 N-m (50 in. lbs.) torque. SEAL
water pump shaft.
(14) Fill cooling system. Refer to Refilling Cooling
System in this group. GROOVE
(15) Connect negative battery cable.
(16) Start and warm the engine. Check for leaks.
WATER PUMP—5.9L DIESEL
REMOVAL WATER
PUMP
(1) Disconnect the negative battery cables from J9107-6
both batteries.
(2) Drain cooling system. Refer to Draining Cool Fig. 59 Pump O-ring Seal—5.9L Diesel
ing System in this section. (7) Start and warm the engine. Check for leaks.
(3) Remove the bolt retaining the wiring harness
near the top of water pump. Position wire harness to WATEi PUMP BYPASS HOSE
the side.
(4) Remove the accessory drive belt. Refer to the REMOWML—3.&L V-6 &m 5,2/B.BL W»S ENGINES
Engine Accessory Drive Belt section of this group. WITHOUT AM CONDITIONING
(5) Remove water pump mounting bolts (Fig. 58). A water pump bypass hose (Fig. 60) is used
between the intake manifold and water pump on all
gas powered engines. To test for leaks, refer to Test
ing Cooling System for Leaks in this group.
ASSEMBLY PUMP
PULLEY PULLEY
BOLTS BYPASS
THREADED
NUT
•"SCREW (2) J9107-5"
Fig. 58 Pump Removal/Installation—5.9L Diesel

(6) Clean water pump sealing surface on cylinder
block.
INSTALLATION THREADED SHAFT CRANKSHAFT

(1) Install new O-ring seal in groove on water (WATER PUMP HUB) PULLEY
pump (Fig. 59).
(2) Install water pump. Tighten mounting bolts to VISCOUS FAN DRIVE
J9307-32
24 N-m (18 ft. lbs.) torque.
(3) Install accessory drive belt. Refer to the Engine Fig. 60 Water Pump Bypass Hose—Typical
Accessory Drive Belt section of this group.
(4) Install the bolt retaining the wiring harness (1) Partially drain cooling system. Refer to Drain
near top of water pump. ing Cooling System i n this group.
(5) Fill cooling system. Refer to Refilling Cooling (2) Do not waste reusable coolant. I f the solution is
System in this section. clean, drain the coolant into a clean container for
(6) Connect both battery cables. reuse.
BR ^ — — — — —~ — COOLING SYSTEM 7 - 43

SUPPORT BRACKET (ROD)
ARE USED ON MOST COOLING SYSTEM HOSES.

tongue of constant tension clamps (Fig. 24). If
(3) Loosen both bypass hose clamps and position to

the center of hose.
^ (4) Remove hose from vehicle.
G E N ERATOR/COMPRESSOR
INSTALLATION M O U N T I N G BRACKET
J9307-66
(1) Position bypass hose clamps to the center of
hose. Fig. 61 Generator—A/C Compressor Mounting
(2) Install bypass hose to engine.
Bracket—Typical
(3) Secure both hose clamps.
(4) Fill cooling system. Refer to Refilling Cooling (8) Remove accessory drive belt. Refer to Belt
System i n this group. Removal/Installation i n the Engine Accessory Drive
(5) Start and warm the engine. Check for leaks. Belt section of this group.
(9) (8) 3.9L V-6 or 5.2/5.9L ¥-8 LDC-Gas: The
REMOVAL—3„BL V-0 OR 5.2/5.9L V-8 ENGINE— drive belt idler pulley must be removed to gain
WITH AIR CONDITIONING access to one of the A/C compressor/generator bracket
I f equipped with A/C, the generator and A/C com mounting bolts. Remove the idler pulley bolt and
pressor along with their common mounting bracket remove idler pulley (Fig. 62).
(Fig. 61) must be partially removed.' Removing the
GENERATOR/COMPRESSOR
generator or A/C compressor from their mounting AND BRACKET
bracket is not necessary. Also, discharging the A/C
system is not necessary. Do not remove any refriger SUPPORT BRACKET
ant lines from A/C compressor.
WARNING: THE A/C SYSTEM IS UNDER PRES

SURE EVEN WITH THE ENGINE OFF. REFER TO
REFRIGERANT WARNINGS IN GROUP 24, HEATING
AND AIR CONDITIONING.

(2) Partially drain cooling system. Refer to Drain
ing Cooling System in this group.
(3) Do not waste reusable coolant. If the solution is
clean, drain the coolant into a clean container for
reuse.
(4) Remove upper radiator hose clamp at radiator.
A special clamp tool (Fig. 23) must be used to remove
the constant tension clamps. Remove hose at radia
\ J9307-33
tor. IGNITION
(5) Disconnect throttle cable from clip at radiator COIL BRACKET
fan shroud.
(6) Unplug wiring harness from A/C compressor. Fig. 62 Idler Pulley—3.9L V-6 or 5.2/5.9L V-8
(7) Remove the air cleaner assembly. LDC-Gas Engines
7 - 44 C O O L I i i SYSTEM BR
REMOVAL A N D INSTALLATION (Continued)
(10) 5.9L HDC-Gas: The automatic belt tensioner/
pulley assembly must be removed to gain access to
one of the A/C compressor/generator bracket mount
ing bolts. Remove the tensioner mounting bolt (Fig.
63) and remove tensioner.
PULLEY
BOLT
TENSIONER
MOUNTING
BOLT
WATER
PUMP J9307-34
Fig. 64 Coolant Return Tube—3.9L V-6 or 5.2/5.9L

V-8 LDC-Gas Engines
COOLANT
TENSIONER RETURN
TUBE
Fig. 63 Beit Tensioner—5.9L HDC-Gas Engine
(11) Remove the engine oil dipstick tube mounting
bolt at the side of the A/C-generator mounting
bracket.
(12) Disconnect throttle body control cables. Refer
to Accelerator Pedal and Throttle Cable in Group 14,
Fuel System.
(13) Remove heater hose coolant return tube
mounting bolt (Fig. 64) (Fig. 65)and remove tube
from engine. Discard the old tube O-ring.
(14) Remove bracket-to-intake manifold bolts
(number 1 and 2 (Fig. 61).
(15) Remove remaining bracket-to-engine bolts TUBE
MOUNTING
(Fig. 66) (Fig. 67). BOLT
(16) Lift and position generator and A/C compres
sor (along with their common mounting bracket) to
gain access to bypass hose. A block of wood may be
used to hold assembly in position. WATER PUMP J9307-61
(17) Loosen and position both hose clamps to the
center of bypass hose. A special clamp tool (Fig. 23) Fig. 65 Coolant Return Tube—5.9L HDC-Gas Engine
must be used to remove the constant tension clamps. (4) Install generator-A/C mounting bracket assem
Remove hose from vehicle. bly to engine. Tighten bolt number 1 (Fig. 61) to 41
N-m (30 ft. lbs.) torque. Tighten bolt number 2 (Fig.
INSTALLATION
61) to 28 N-m (20 ft. lbs.) torque. Tighten bracket
(1) Position bypass hose clamps to the center of mounting bolts (Fig. 66) (Fig. 67)to 40 N-m (30 ft.
hose. lbs.) torque.
(2) Install bypass hose to engine. (5) Install a new O-ring to the heater hose coolant
(3) Secure both hose clamps. return tube (Fig. 64) (Fig. 65). Coat the new O-ring
with antifreeze before installation.
SYSTEM 7 - 45
t E M O V A L AND INSTALLATION (Continued)

(10) 5.9L HDC-Gas: Install automatic belt ten
sioner assembly to mounting bracket. A dowel pin is
located on back of tensioner (Fig. 68). Align this to
dowel hole (Fig. 69) in tensioner mounting bracket.
Tighten bolt to 41 N-m (30 ft. lbs.) torque.
BELT TENSIONER
DOWEL PIN J9307-63
Fig. 68 Tensioner Dowel Pin—5.9L HDC-Gas Engine

Fig. 66 Bracket Bolts—3.9L ¥-6 or 5.2/5.9L ¥-8
LDC-Gas Engines
Fig. 69 Tensioner Mounting Bracket Dowel

Hole—5.9L HDC-Gas Engine
(11) Install drive belt. Refer to Belt Removal/In
stallation in the Engine Accessory Drive Belt section
of this group.
CAUTION: When installing the serpentine acces

sory drive belt, the belt must be routed correctly. If
Fig. 67 Bracket Bolts—5.9L HDC-Gas Engine not, the engine may overheat due to the water
(6) Install coolant return tube and its mounting pump rotating in the wrong direction. Refer to Belt
bolt to engine (Fig. 64) (Fig. 65). Schematics in the Engine Accessory Drive Belt sec
(7) Connect throttle body control cables. tion of this group for correct belt routing. The cor
(8) Install oil dipstick mounting bolt. rect belt with the correct length must be used.
(9) 3.9L V-6 or 5.2/5.9L V-8 LDC-Gas Engines:
(12) Install air cleaner assembly.
Install idler pulley. Tighten bolt to 41 N-m (30 ft.
(13) Install upper radiator hose to radiator.
lbs.) torque.
7 - 46 COOLING SYSTEM — mm
(14) Connect throttle cable to clip at radiator fan
shroud.
(15) Connect wiring harness to A/C compressor.
System in this group.
(17) Start and warm the engine. Check for leaks.
THERMOSTAT—3.9L V-6 OR 5.2/5.9L V-8
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR

DRAINCOCK WITH THE SYSTEM HOT AND PRES
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
Do not waste reusable coolant. I f the solution is

Fig. 70 Support Bracket—Generator Mounting
Bracket-to-intake Manifold—Typical
reuse.
I f the thermostat is being replaced, be sure that CAUTION: A number or letter Is stamped into the
the replacement is the specified thermostat for the tongue of constant tension clamps (Fig. 24). If
vehicle model and engine type. replacement is necessary, use only an original
Factory installed thermostat housings on 3.9L V-6 equipment clamp with a matching number or letter.
or 5.2/5.9L V-8 engines are installed on a gasket with
an anti-stick coating. This will aid in gasket removal (4) Remove upper radiator hose clamp. Remove
and cleanup. upper radiator hose at thermostat housing.
(1) Disconnect negative battery cable at battery. (5) Position the wiring harness (behind the ther
(2) Drain cooling system until coolant level is mostat housing) to gain access to thermostat hous
below thermostat. Refer to Draining Cooling System ing.
in this group. I f not equipped with air conditioning, (6) Remove thermostat housing mounting bolts,
proceed to step number 4. thermostat housing, gasket and thermostat (Fig. 71).
(3) I f equipped with air conditioning: Discard old gasket.
(a) Remove the support bracket (rod) located
near the rear of generator (Fig. 70).
(b) The drive belt must be removed. Refer to
Belt Removal/Installation in the Engine Accessory
Drive Belt section of this group.
(c) The generator must be partially removed.
Remove the two generator mounting bolts. Do not
remove any wiring at generator. I f equipped with
4WD, unplug the 4WD indicator lamp wiring har
ness (located near rear of generator).
(d) Remove generator. Position generator to gain
access for thermostat gasket removal.

WHEN REMOVING OR INSTALLING, USE ONLY •THERMOSTAT
6094) (Fig. 23). SNAP-ON CLAMP TOOL (NUMBER MACHINED GROOVE
J9207-14
Fig. 71 Thermostat—3.9L V-6 or 5.2/5.9L V-8 Gas
Engines

INSTALLATION CAUTION: When installing the serpentine acces
(1) Clean mating areas of intake manifold and sory drive belt, the belt must be routed correctly. If
thermostat housing. not, the engine may overheat due to the water
(2) Install thermostat (spring side down) into pump rotating in the wrong direction. Refer to Belt
recessed machined groove on intake manifold (Fig. Schematics in the Engine Accessory Drive Belt sec
71). tion of this group for correct engine belt routing.
(3) Install gasket on intake manifold and over The correct belt with the correct length must be
thermostat (Fig. 71). used.
(4) Position the thermostat housing to the intake
manifold. Note the word FRONT stamped on the (8) Fill cooling system. Refer to Refilling Cooling
housing (Fig. 72). For adequate clearance, this must System in this group.
be placed towards the front of vehicle. The housing (9) Connect negative battery cable to battery.
should be slightly angled forward after installation to (10) Start and warm engine. Check for leaks.
intake manifold.
THERMOSTAT—8.0L V-10
MEMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR

DRAINCOCK WITH THE SYSTEM HOT AND PRES
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
Do not. waste reusable coolant. I f the solution is

reuse.
If the thermostat is being replaced, be sure that
the replacement is the specified thermostat for the
vehicle model and engine type.
A rubber lip-type seal with a metal shoulder is
pressed into the intake manifold beneath the thermo
stat (Fig. 73).
Fig. 72 Thermostat Position—3.91 V-6 or 5.2/5.9L

V-8 Gas Engines
(5) Install two housing-to-intake manifold bolts.
Tighten bolts to 23 N-m (200 in. lbs.) torque.
CAUTION: Housing must be tightened evenly and

thermostat must be centered into recessed groove
in intake manifold. If not, it may result in a cracked
housing, damaged intake manifold threads or cool
ant leak.
(6) Install upper radiator hose to thermostat hous Fig. 73 Thermostat Seal—8.0L V-10 Engine
ing.
(1) Disconnect negative battery cable at battery.
(7) Air conditioned vehicles:
(2) Drain cooling system until coolant level is
(a) Install generator. Tighten bolts to 41 N-m (30
below thermostat. Refer to Draining Cooling System
ft. lbs.) torque.
in this group.
(b) Install support bracket (generator mounting
(3) Remove' the two support rod mounting bolts
* bracket-to-intake manifold) (Fig. 70). Tighten bolts
and remove support rod (intake manifold-to-genera
tor mount) (Fig. 74).
R E M O V A L AN© INSTALLATION (Continued)
TEMP. COOLANT
Fig. 74 Support Rod—8.0L ¥-10 Engine

6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20)
MAY BE USED FOR LARGER CLAMPS. ALWAYS
WEAR SAFETY GLASSES WHEN SERVICING CON
STANT TENSION CLAMPS.
RUBBER LIP SEAL J9407-16
CAUTION: A number or letter is stamped into the Fig. 75 Thermostat—8. OL ¥-10 Engine
tongue of constant tension clamps. If replacement (6) Install housing-to-intake manifold bolts.
is necessary, use only an original equipment clamp
with a matching number or letter.
CAUTION: Housing bolts should be tightened
(4) Remove upper radiator hose clamp. Remove
evenly to prevent damage to housing and to pre
upper radiator hose at thermostat housing.
vent leaks.
(5) Disconnect the wiring connectors at both of the
sensors located on thermostat housing. (7) Connect the wiring to both sensors.
(6) Remove six thermostat housing mounting bolts, (8) Install the upper radiator hose and hose clamp
thermostat housing, gasket and thermostat. Discard to thermostat housing.
old gasket. (9) Install support rod.
INSTALLATION.
System i n this group.
(1) Clean mating areas of intake manifold and (11) Connect negative battery cable to battery.
thermostat housing. (12) Start and warm engine. Check for leaks.
(2) Check the condition (for tears or cracks) of the
rubber thermostat seal located in the intake manifold THERMOSTAT—DIESEL ENGINE
(Fig. 73) (Fig. 75). The thermostat should fit snugly
into the rubber seal. REMOVAL
(3) I f seal replacement is necessary, coat the outer
(metal) portion of the seal with Mopar® Gasket WARNING: DO NOT LOOSEN THE RADIATOR
Maker. Install the seal into the manifold using Spe DRAINCOCK WITH THE SYSTEM HOT AND PRES
cial Seal Tool number C-3995-A with handle tool SURIZED. SERIOUS BURNS FROM THE COOLANT
number C-4171. CAN OCCUR.
(4) Install thermostat into recessed machined
groove on intake manifold (Fig. 75). Do not waste reusable coolant. I f the solution is
(5) Install gasket on intake manifold and over clean, drain the coolant into a clean container for
thermostat (Fig. 75). reuse.
REMOVAL AN© INSTALLATION (Continued)

(1) Disconnect both negative battery cables from
both batteries.
(2) Remove accessory drive belt. Refer to Belt
Removal/Installation in the Engine Accessory Drive
Belt section in this group.
(3) Drain cooling system until coolant level is
below thermostat. Refer to Draining Cooling System
in this section. BRACKET
SOUS
WARNING: CONSTANT TENSION HOSE CLAMPS MOUNTING
ARE USED ON MOST COOLING SYSTEM HOSES. BRACKET


tongue of constant tension clamps (Fig. 24). If GENERATOR J9407-13
equipment clamp with a matching number or letter. Fig. 77 Generator Mounting Bracket Bolts—Diesei
(11) Remove the thermostat housing, thermostat,
(4) Remove radiator hose clamp and hose from inner and outer seals and lift bracket (Fig. 76).
thermostat housing. A special clamp tool (Fig. 23) (12) Clean the mating surfaces of the thermostat
must be used to remove the constant tension clamps. housing and the cylinder head.
(5) Remove the hose clamp and check valve hose
at thermostat housing (Fig. 76). mSWMLLMTIOm
(1) Install the outer seal (Fig. 76) (Fig. 78)into the
HOUSING HOSE LIFT
BRACKET machined shoulder on the thermostat housing.
(2) Install the thermostat into the machined shoul
der next to the outer seal. Note direction of thermo
stat in (Fig. 76) (Fig. 78).
(3) Position the inner thermostat seal with the
shoulder towards the thermostat housing (Fig. 78).
LIFT
BRACKET
THERMOSTAT
HOUSING OUTER THERMOSTAT

INNER
BOLTS SEAL J9507-22
SEAL
Fig. 76 Thermostat Removal—5.9L Diesei

(6) Remove the two upper generator bracket
mounting bolts (Fig. 77).
(7) Remove the upper generator mounting bracket
(Fig. 77). OUTER
(8) Loosen but do not remove the generator lower SEAL SHOULDER J9507-23
pivot bolt.
(9) Position the generator to gain access to thermo Fig. 78 Thermostat Seals—5.9L Diesel—Typical
stat housing and housing bolts.
(10) Remove thermostat housing mounting bolts.
R E M O V A L mm msmLLMfmm (Continued)
(4) Install thermostat, lift bracket, seals and hous (6) Disconnect the windshield washer reservoir
ing to the engine as an assembly. Install and tighten tank at the fan shroud. Refer to Group 8K, Wind
mounting bolts to 24 N-m (18 ft. lbs.) torque. shield Wiper and Washer Systems for procedures.
(5) Position generator to thermostat housing. (7) Remove the rubber shield at right side of radi
Install and tighten mounting bolt to 24 N-m torque. ator. The shield is held to vehicle body with plastic
Tighten pivot bolt to 43 N-m (32 ft. lbs.) torque. clips.
(6) Install the check valve hose and hose clamp at (8) Remove the two radiator upper mounting bolts
thermostat housing (Fig. 76). (Fig. 79).
(7) Install accessory drive belt. Refer to Belt
MOUNTING
Removal/Installation in the Engine Accessory Drive BOLTS
Belt section of this group.
(8) Connect negative battery cables to both batter
ies.
(9) Fill cooling system and check for leaks. Refer
to Refilling Cooling System in this group.
REPLACING WATER-TO-OIL COOLER IN RADIATOR

SIDE TANK
The internal transmission oil cooler located within
the radiator is not serviceable. I f it requires service,
the radiator must be replaced.
Once the repaired or replacement radiator has
been installed, fill the cooling system and inspect for
leaks. Refer to the Refilling Cooling System and Test
ing Cooling System For Leaks sections in this group.
I f the transmission operates properly after repairing
the leak, drain the transmission and remove the
transmission oil pan. Inspect for sludge and/or rust. ALIGNMENT
Inspect for a dirty or plugged inlet filter. I f none of DOWELS (2) J9407-38
these conditions are found, the transmission and
torque convertor may not require reconditioning. Fig. 79 Radiator Mounting Bolts—Typical
Refer to Group 21 for automatic transmission servic
(9) Position the upper part of radiator towards
ing.
engine.
(10) Remove the oil cooler lower mounting bolt (oil
AifFTO-OlL COOLER—3 J L / I . 2 L / 1 J L ENGINES.,
cooler-to- vehicle body) (Fig. 80).
REMOVAL (11) Remove three bolts (radiator support bracket-
to-body). Remove this A-shaped support bracket and
CAUTION: If a leak should occur in the internal the transmission oil cooler as an assembly from the
radiator mounted transmission air-to-oil cooler (gas vehicle. Take care not to damage the radiator core or
engines only), engine coolant may become mixed A/C condenser fins with the cooling lines when
with transmission fluid. Transmission fluid may also removing.
enter engine cooling system. Both cooling system (12) Remove oil cooler from A-shaped support
and transmission should be drained and inspected bracket by removing two upper mounting strap bolts
in case of oil cooler leakage. and mounting straps at support bracket (Fig. 80).
(13) Remove oil cooler from the A-shaped radiator
(1) Disconnect negative battery cable at battery. support bracket.
(2) Drain cooling system. Refer to Draining Cool
ing System. INSTALLATION
(3) Place a drain pan under the oil cooler lines. (1) Install the oil cooler assembly to the A-shaped
(4) Disconnect the two transmission oil cooler line radiator support bracket using the two upper mount
quick-connect fittings at the radiator. Refer to Group ing bolts and mounting straps. Install the bolts but
21, Transmissions for procedures. Plug cooler lines to do not tighten at this time.
prevent oil leakage. (2) Install the radiator support bracket and oil
(5) Disconnect the oil cooler quick-connect fitting cooler (as an assembly) to the vehicle.
at the transmission oil cooler line. Refer to Group 21, (3) Install the two lower radiator A-shaped support
Transmissions for procedures. bracket bolts. Do not tighten bolts at this time.
REMOVAL A N D I N S T A L L A T I O N (Continued)
UPPER RADIATOR TRANS. OIL and transmission should be drained and inspected
SUPPORT BRACKET COOLER in case of oil cooler leakage.
BOLT UPPER
MOUNTING
RADIATOR
BOLTS (2)
(1) Place a drain pan under the oil cooler lines.
SUPPORT
BRACKET
(2) Disconnect the two transmission oil cooler line
quick-connect fittings from the transmission oil
TRANSMISSION
OIL
cooler lines (Fig. 81). Refer to Group 21, Transmis
COOLER sions for procedures. Plug cooler lines to prevent oil
leakage.
(3) Remove three oil cooler-to-radiator support
mounting bolts (Fig. 81).
(4) Remove the oil cooler and line assembly from
the vehicle.
RADIATOR
SUPPORT
TRANS.
LOWER RADIATOR OIL C O O L E R
SUPPORT BRACKET TRANS. OIL
BOLTS (2) COOLER
LOWER
MOUNTING TRANS. OIL
BOLT J9407-40 C O O L E R LINES
Fig. 80 AiMo-oii Cooler 3.9L or 5.2/5.9L Engines

(4) Slide and position the oil cooler on the
A-shaped bracket until its lower mounting hole lines
up with the bolt hole on the vehicle body. Tighten the
oil cooler mounting strap bolts to 6 N-m (50 in. lbs.)
torque.
(5) Install the upper radiator A-shaped support
QUICK-CONNECT
bracket bolt. Tighten all three radiator support FITTINGS
bracket mounting bolts to 11 N-m (95 in. lbs.) torque. (2)
(6) Install the two radiator upper mounting bolts OIL COOLER
(Fig. 79). Tighten bolts to 11 N-m (95 in. lbs.) torque. MOUNTING
(7) Install windshield washer reservoir tank. BOLTS (3) J9407-41
(8) Install rubber shield to radiator.
(9) Install the quick-connect fittings on the two oil Fig. 81 Air To Oil Cooler—V-10 Engine
cooler lines to the radiator. Refer to Group 21, Trans INSTALLATION
missions for procedures. (1) Install the oil cooler and cooler line assembly to
(10) Fill cooling system. Refer to Refilling the the vehicle.
Cooling System in this group. (2) Install three mounting bolts and tighten to 6
(11) Connect negative battery cable to battery. N-m (50 in. lbs.) torque.
(12) Start the engine and check all fittings for (3) Connect the quick-connect fittings. Refer to
leaks. Group 21, Transmissions for procedures.
(13) Check the fluid level in the automatic trans (4) Start the engine and check all fittings for
mission. Refer to Group 21, Transmissions for proce leaks.
dures. (5) Check the fluid level in the automatic trans
mission. Refer to Group 21, Transmissions for proce
A1R-T0-01L COOLER—8 J L ¥ 4 0 ENGINE dures.
REM0WAL
CAUTION: If a leak should occur in the internal

radiator mounted transmission oil cooler (gas
engines only), engine coolant may become mixed
with transmission fluid. Transmission fluid may also
enter engine cooling system. Both cooling system

WATER-TO-OIL COOLER—5.9L DIESEL ENGINE AIR-TO-OIL COOLER—5 J L DIESEL ENGINE
REMOVAL REMOVAL
(1) Remove front bumper. Refer to Group 23, Body.
CAUTION: If a leak should occur in the water-to-oil (2) Place a drain pan under the oil cooler.
cooler mounted to the side of the engine block, (3) Raise the vehicle.
engine coolant may become mixed with transmis (4) Disconnect the oil cooler quick-connect fittings
sion fluid. Transmission fluid may also enter engine from the transmission lines. These are located near
cooling system. Both cooling system and transmis the power steering gearbox. Refer to Group 21,
sion should be drained and inspected in case of oil Transmissions for procedures.
cooler leakage. (5) Remove the charge air cooler-to-oil cooler bolt
(Fig. 83).
(1) Disconnect both negative battery cables at bat
teries. C H A R G E AIR
C O O L E R (INTERCOOLER)
(2) Remove air cleaner assembly and air cleaner
intake hoses. Refer to Group 14, Fuel System for pro
cedures.
(3) Drain cooling system. Refer to Draining Cool TRANSMISSION
ing System. OIL C O O L E R
(4) Disconnect coolant lines from cooler.
(5) Disconnect transmission oil lines from cooler.
Plug cooler lines to prevent oil leakage.
(6) Remove oil cooler mounting straps (Fig. 82).
TRANSMISSION
WATER-TO-OIL
COOLER
QUICK-
MOUNTING CONNECT
NUTS (2) FITTINGS (2) J9407-42
Fig. 83 Air-to-Oil Cooler—Diesel Engine

(6) Remove two mounting nuts.
J9407-47 (7) Remove the oil cooler and line assembly
towards the front of vehicle. Cooler must be rotated
Fig. 82 Transmission Water-To- Oil Cooler—Diesel and tilted into position while removing.
(7) Lift oil cooler off of mounting bracket. INSTALLATION
(1) Carefully position the oil cooler assembly to the
INSTALLATION
vehicle.
(1) Position oil cooler on bracket. (2) Install two nuts and one bolt. Tighten to 11
(2) Install mounting straps. N-m (95 in. lbs.) torque.
(3) Connect transmission oil lines to cooler. (3) Connect the quick-connect fittings to the trans
(4) Connect coolant hoses to cooler. mission cooler lines. Refer to Group 21, Transmis
(5) Connect negative battery cables to both batter sions for procedures.
ies. (4) Install front bumper. Refer to Group 23, Body.
(5) Start the engine and check all fittings for
System in this section.
leaks.
(7) Check transmission oil level and fill as neces
(6) Check the fluid level i n the automatic trans
sary.
mission. Refer to Group 21, Transmissions for proce
(8) Install air cleaner assembly and air cleaner
dures.
intake hoses. Refer to Group 14, Fuel System for pro
cedures.
mm COOLING SYSTEM 7 - 53
R E M O V A L A N D INSTALLATION (Continued)
RADIATOR (11) Remove the four fan shroud mounting bolts

(Fig. 84). Position shroud rearward over the fan
REMOVAL—ALL ENGINES blades towards engine.
(1) A l l Engines Except Diesel: Disconnect nega RADIATOR
tive battery cable from battery.
(2) Diesel engine: Disconnect both negative bat
tery cables at both batteries. Remove the nuts retain
ing the positive cable to the top of radiator. Position
positive battery cable to rear of vehicle.
WARNING: DO NOT REMOVE THE CYLINDER

BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR.
(3) Drain the cooling system. Refer to Draining

Cooling System in this group.
(4) Disconnect throttle cable from clip at top of
radiator fan shroud.

TOOLS DESIGNED FOR SERVICING THIS TYPE OF FAN SHROUD M O U N T I N G BOLTS J9407-37
6094) (Fig. 23). SNAP-ON CLAMP TOOL (NUMBER Fig. 84 Typical Fan Shroud Mounting
HPC-20) MAY BE USED FOR LARGER CLAMPS. (12) A l l Engines Except 8.0L V-10 and Diesel:
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC Except 8.0L V-10 and Diesel: Remove the plastic clips
ING CONSTANT TENSION CLAMPS. retaining the rubber shields to the sides of radiator.
Position rubber shields to the side.
(13) Remove the two radiator upper mounting
tongue of constant tension clamps (Fig. 24). If bolts (Fig. 85).
replacement is necessary, use only an original MOUNTING
equipment clamp with a matching number or letter. BOLTS
(5) Remove hose clamps and hoses from radiator.

(6) A l l engines: Remove coolant reserve/overflow
tank hose from radiator filler neck nipple.
(7) All engines except 8.0L V-10: Remove the cool
ant reserve/overflow tank from the fan shroud (pull
straight up). The tank slips into T-slots on the fan
shroud.
(8) Disconnect electrical connectors at windshield
washer reservoir tank and remove tank. Refer to
Group 8K, Windshield Wiper and Washer Systems
for procedures.
(9) If equipped with an automatic transmission (all
engines except diesel), disconnect oil cooler lines
(hoses) at radiator tank. Refer to Group 21, Trans
missions for procedures.
(10) Diesel Engine Only: Remove the two metal
clips retaining the upper part of fan shroud to the ALIGNMENT
top of radiator. DOWELS (2) J9407-38
Fig. 85 Typical Radiator Mounting

(14) Lift radiator straight up and out of engine (2) Drain coolant from radiator and cylinder block.
compartment. The bottom of the radiator is equipped (3) Remove power cord from heater by unplugging
with two alignment dowels that fit into holes in the (Fig. 86) (Fig. 87). On the diesel engine, the cord is
lower radiator support panel (Fig. 85). Rubber bis connected to the heater with a knurled cap. Unscrew
cuits (insulators) are installed to these dowels. Take this cap for cord removal.
care not to damage cooling fins or tubes on the radi (4) Loosen (but do not completely remove) the
ator and air conditioning condenser when removing. screw at center of block heater (Fig. 86) (Fig. 87). On
the diesel engine, an alien headed screw is used.
INSTALLATION (5) Remove block heater from engine by carefully
(1) Position fan shroud over the fan blades rear prying from side- to-side. When removing block
ward towards engine. heater, note direction of heating element coil (up or
(2) Install rubber insulators to alignment dowels down). Element coil must be installed correctly to
at lower part of radiator. prevent damage.
(3) Lower the radiator into position while guiding
the two alignment dowels into lower radiator sup
port. Different alignment holes are provided in the
lower radiator support for each engine application.
(4) Install two upper radiator mounting bolts.
(5) 3.9L V-6 or 5.2L/5.9L V-8 Engines: Position the
rubber shields to the sides of radiator. Install the
plastic clips retaining the rubber shields to the sides
of radiator.
(6) Connect both radiator hoses. Refer to previous
CAUTION and install hose clamps.
(7) I f equipped, connect transmission oil cooler
lines to radiator tank. Refer to Group 21, Transmis
sions for procedures.
(8) Install windshield washer reservoir tank. Refer
to Group 8K.
(9) Position fan shroud to flanges on sides of radi
ator. Install fan shroud mounting bolts (Fig. 84).
(10) Diesel Engines: Install metal clips to top of
fan shroud.
(11) A l l engines: Install coolant reserve/overflow
tank hose to radiator filler neck nipple. Fig. 86 Engine Block Heater—3.9L/5.2L/5.9L Gas
(12) All Engines Except 8.0L V-10: Install coolant Powered Engine
reserve/overflow tank to fan shroud (fits into T-slots INSTALLATION
on shroud). (1) Thoroughly clean the cylinder block freeze plug
(13) Connect throttle cable to fan shroud. hole and block heater seat.
(14) Install negative battery cable to battery. (2) Install new O-ring seal(s) to heater.
(15) Diesel Engine: Install positive battery cable (3) Insert block heater into cylinder block.
to top of radiator. Tighten radiator-to-battery cable (4) With heater fully seated, tighten center screw.
mounting nuts. (5) Fill cooling system with recommended coolant.
(16) Position heater controls to full heat position. Refer to Refilling Cooling System section in this
(17) Fill cooling system with coolant. Refer to group.
Refilling Cooling System in this group. (6) Start and warm the engine.
(18) Operate engine until it reaches normal tem (7) Check block heater for leaks.
perature. Check cooling system and automatic trans
mission (if equipped) fluid levels.
ENGINE 1L0C1 HE1TER
REMOVAL
(1) Disconnect negative battery cable(s) from bat-
tery(s).
REMOVAL AH© INSTALLATION (Continued)
Fig. 87 Engine Block Heater—8.OL V-10 Engine Fig. 88 Belt Tensioner—3.9L V-6 or 5.2/5.9L V-8
LDC-Gas Engines
SERPENTINE ORifE BELTS
IISTALLATIOI
NOTE: The belt routing schematics are published
from the latest information available at the time of CAUTION: When installing serpentine accessory
publication. If anything differs between these sche drive belt, the belt must be routed correctly. If not,
matics and the Belt Routing Label, use the sche engine may overheat due to water pump rotating in
matics on Belt Routing Label.This label is located in wrong direction. Refer to (Fig. 89) for correct engine
the engine compartment. belt routing. The correct belt with correct length
must be used.
CAUTION: Do not attempt to check belt tension (1) Position drive belt over all pulleys except idler
with a belt tension gauge on vehicles equipped with pulley. This pulley is located between generator and
an automatic belt tensioner. Refer to Automatic Belt A/C compressor.
Tensioner in this group. (2) Attach a socket/wrench to pulley mounting bolt
of automatic tensioner (Fig. 88).
(3) Rotate socket/wrench clockwise. Place belt over
3.9L V-6 OR 5.2/5.9L V-8 LDC-GAS ENGINES idler pulley. Let tensioner rotate back into place.
Remove wrench. Be sure belt is properly seated on
REMOVAL
all pulleys.
Drive belts on these engines are equipped with a (4) Check belt indexing marks. Refer to the pro
spring loaded automatic belt tensioner (Fig. 88). This ceeding Automatic Belt Tensioner for more belt infor
belt tensioner will be used on all belt configurations, mation.
such as with or without power steering or air condi
tioning. For more information, refer to Automatic 5.9L HDC-GAS AND 8.0L V-10 ENGINES
Belt Tensioner, proceeding in this group.
(1) Attach a socket/wrench to pulley mounting bolt REMOVAL
of automatic tensioner (Fig. 88). Drive belts are equipped with a spring loaded auto
(2) Rotate tensioner assembly clockwise (as viewed matic belt tensioner (Fig. 90). This belt tensioner will
from front) until tension has been relieved from belt. be used on all belt configurations, such as with or
(3) Remove belt from idler pulley first. without power steering or air conditioning. For more
(4) Remove belt from vehicle. information, refer to Automatic Belt Tensioner, pro
ceeding in this group.
1ISTALLAT10N
CAUTION: When installing serpentine accessory

drive belt, the belt must be routed correctly. If not,
engine may overheat due to water pump rotating in
wrong direction. Refer to (Fig. 91) (Fig. 92)for cor
rect engine belt routing. The correct belt with cor
rect length must be used.
CAUTION: If the pulley is to be removed from the

tensioner, its mounting bolt has left-hand threads.
(1) Position drive belt over all pulleys except ten

sioner pulley.
(2) Attach a socket/wrench to pulley mounting bolt
of automatic tensioner (Fig. 90).
(3) Rotate socket/wrench counterclockwise. Install
belt over tensioner pulley. Let tensioner rotate back
into place. Remove wrench. Be sure belt is properly
* ! F VEHICLE IS NOT EQUIPPED WITH POWER seated on all pulleys.
STEERING, THIS WILL BE A N IDLER PULLEY, J9307-26
AUTOMATIC
Fig. 89 Belt Routing—3.9L V-6 or 5.2/5.9L V-8 TENSIONER
LDC-Gas Engines
J9307-55
Fig. 91 Belt Routing—5.9L HDC-Gas Engine and 8.0

L V-10—With A/C
5.9L DIESEL ENGINE
Fig. 90 Belt Tensioner—5.9L HDC-Gas and 8.0L V-10
REMOVAL
Engines—Typical
Drive belts on diesel engines are equipped with a
(1) Attach a socket/wrench to pulley mounting bolt spring loaded automatic belt tensioner (Fig. 93).
of automatic tensioner (Fig. 90). The threads on the (Fig. 93) displays the tensioner for vehicles
pulley mounting bolt are left- hand. without air conditioning.
(2) Relax the tension from the belt by rotating the This belt tensioner will be used on all belt config
tensioner counterclockwise (as viewed from front) urations, such as with or without air conditioning.
(Fig. 90). When all belt tension has been relaxed, For more information, refer to Automatic Belt Ten
remove belt from tensioner pulley first and other pul sioner, proceeding in this group.
leys last.
B R _ _ _ _ _ _ _ — COOLING SYSTEM 7 - 57
AUTOMATIC
wrong direction. Refer to (Fig. 94) (Fig. 95)for cor
TENSIONER rect engine belt routing. The correct belt with cor
rect length must be used.
(1) Position drive belt over all pulleys except

water pump pulley.
(2) Attach a 3/8 inch ratchet to tensioner.
(3) Rotate ratchet and belt tensioner counterclock
wise. Place belt over water pump pulley. Let ten
sioner rotate back into place. Remove ratchet. Be
sure belt is properly seated on all pulleys.
* POWER STEERING PUMP IS NOT BELT DRIVEN
J9307-56
Fig. 92 Beit Routing—5.9L HDC-Gas Engine and 8.0

I v-10—Without A/C
Fig. 94 Belt Routing—5.9L Diesei Engine—With A/C

AUTOMATIC BELT TENSIONER
NOTE: On 3.9L V-6 or 5.2/5.9L V-8 LDC-gas engines,

the tensioner is equipped with an indexing arrow
(Fig. 96) on back of tensioner and an indexing mark
on tensioner housing. If a new belt is being
Fig. 98 Beit Tensioner—5.9L Diesei—Typical installed, arrow must be within approximately 3 mm
(non-A/C shown) (1/8 in.) of indexing mark (point B-) (Fig. 96). Belt is
(1) A 3/8 inch square hole is provided in the auto considered new if it has been used 15 minutes or
matic belt tensioner (Fig. 93). Attach a 3/8 inch less. If this specification cannot be met, check for:
drive-long handle ratchet to this hole. • The wrong belt being installed (incorrect
(2) Rotate ratchet and tensioner assembly counter length/width)
clockwise (as viewed from front) until tension has • Worn bearings on an engine accessory (A/C
been relieved from belt. compressor, power steering pump, water pump,
(3) Remove belt from water pump pulley first. idler pulley or generator)
(4) Remove belt from vehicle. • A pulley on an engine accessory being loose
• Misalignment of an engine accessory
INSTALLATION • Belt incorrectly routed.
On 3.9L V-6 or 5.2/5.9L V-8 LDC-gas engines, a
CAUTION: When installing serpentine accessory used belt should be replaced if tensioner indexing
drive belt, the belt must be routed correctly. If not, arrow has moved to point-A (Fig. 96). Tensioner
engine may overheat due to water pump rotating in travel stops at point-A.
R E M O V A L A N D 1 INSTALLATION fContinued)
3,BL W°6 OR 5*2/5*91 ¥-8 LDC-GAS EMGINES
REMOVAL
Removal/Installation in this group.
(2) Disconnect wiring and secondary cable from
ignition coil.
(3) Remove ignition coil from coil mounting
bracket (two bolts). Do not remove coil mounting
bracket from cylinder head.
(4) Remove tensioner assembly from mounting
bracket (one nut) (Fig. 96).
WARNING: BECAUSE OF HIGH SPRING PRES

SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO
MATIC TENSIONER. UNIT IS SERVICED AS AN
ASSEMBLY (EXCEPT FOR PULLEY).
(5) Remove pulley bolt. Remove pulley from ten

sioner.
I1STALLATI01
(1) Install pulley and pulley bolt to tensioner.
Fig. 95 Belt Routing—5.9L Diesei Engine—Without
A/C
(2) Install tensioner assembly to mounting
TENSIONER bracket. An indexing tab is located on back of ten
ASSEMBLY
sioner. Align this tab to slot in mounting bracket.
Tighten nut to 67 N-m (50 ft. lbs.) torque.
(3) Connect all wiring to ignition coil.
(4) Install coil to coil bracket. I f nuts and bolts are
used to secure coil to coil bracket, tighten to 11 N-m
(100 in. lbs.) torque. I f coil mounting bracket has
been tapped for coil mounting bolts, tighten bolts to 5
N-m (50 in. lbs.) torque.
INDEXING CAUTION: To prevent damage to coil case, coil

ARROW mounting bolts must be torqued.
(5) Install drive belt. Refer to Belt Removal/Instal

lation in this group.
(6) Check belt indexing marks (Fig. 96).
5.BL HDC-GAS AMD 8.0L V-10 ENGINES
REMOVAL
(2) Remove tensioner mounting bolt (Fig. 97) and
remove tensioner.
CAUTION: If the pulley is to be removed from the

tensioner, its mounting bolt has left-hand threads.
Fig. 96 Indexing Marks—3.91 ¥-6 or 5.2/5.9L ¥-8 WARNING: BECAUSE OF HIGH SPRING PRES
LDC-Gas Engines SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO
MATIC TENSIONER. UNIT IS SERVICED AS AN
ASSEMBLY (EXCEPT FOR PULLEY).
BR — — COOLING SYSTEM 7 - 59
Fig. 99 Tensioner Dowel Hole—5.9L HDC-Gas and

8.0L V-10 Engines
5.9L DIESEL ENGINE
REMOVAL
Fig. 97 Belt Tensioner—SSL HDC-Gas and 8.0L v-10 (1) Remove accessory drive belt. Refer to Belt
INSTALLATION
(2) Remove tensioner mounting bolt (Fig. 97) and
(1) Install pulley and pulley bolt to tensioner
remove tensioner.
(observe the previous CAUTION). Tighten bolt to 88
N-m (65 ft. lbs.) torque. WARNING: BECAUSE OF HIGH SPRING PRES
(2) Install tensioner assembly to mounting SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO
bracket. A dowel pin is located on back of tensioner MATIC TENSIONER. UNIT IS SERVICED AS AN
(Fig. 98). Align this to dowel hole (Fig. 99) in ten ASSEMBLY (EXCEPT FOR PULLEY).
sioner mounting bracket. Tighten bolt to 41 N-m (30
ft. lbs.) torque.
INSTALLATION •
BELT TENSIONER (1) Install pulley to tensioner.
(2) Install tensioner assembly to mounting
bracket. A dowel is located on back of tensioner. Align
this dowel to hole in tensioner mounting bracket.
(3) Install drive belt. Refer to Belt Removal/Instal
lation in this group.
COOLING SYSTEM FAN—GAS ENGINES
REMOWAL
CAUTION: If the viscous fan drive is replaced

because of mechanical damage, the cooling fan
DOWEL PIN J9307-63 blades should also be inspected. Inspect for fatigue
cracks, loose blades, or loose rivets that could
Fig. 98 Tensioner Dowel Pin—5.9L HDC-Gas and have resulted from excessive vibration. Replace fan
8.0L V-10 Engines blade assembly if any of these conditions are
(3) Install drive belt. Refer to Belt Removal/Instal found. Also inspect water pump bearing and shaft
lation in this group. assembly for any related damage due to a viscous
fan drive malfunction.

(2) Remove throttle cable at top of fan shroud.
HEH©WAL AMD INSTALLATION fContlmuecfl

(3) A l l Except 8.0L V-10 Engine: Unsnap coolant (10) Remove four bolts securing fan blade assem
re serve/overflow tank from fan shroud and lay aside. bly to viscous fan drive (Fig. 100).
The tank is held to shroud with T- shaped slots. Do
not disconnect hose or drain coolant from tank. CAUTION: Some engines equipped with serpentine
(4) The thermal viscous fan drive/fan blade assem drive belts have reverse rotating fans and viscous
bly is attached (threaded) to water pump hub shaft fan drives. They are marked with the word
(Fig, 100). Remove fan blade/viscous fan drive assem REVERSE to designate their usage. Installation of
bly from water pump by turning mounting nut coun the wrong fan or viscous fan drive can result in
terclockwise as viewed from front. Threads on engine overheating.
viscous fan drive are EIGHT-HAND, A Snap-On 36
M M Fan Wrench (number SP346 from Snap-On
fffSFALLATfOfi
Cummins Diesel Tool Set number 2017DSP) can be
(1) Install fan blade assembly to viscous fan drive.
used. Place a bar or screwdriver between water
Tighten bolts (Fig. 100) to 23 N-m (17 ft. lbs.) torque.
pump pulley bolts (Fig. 100) to prevent pulley from
rotating.
(5) Do not attempt to remove fan/viscous fan drive
(3) Install fan shroud.
assembly from vehicle at this time.
FAN BLADE WATER WATER PUMP water pump shaft (Fig. 100).
(5) Except 8.0L V-10 Engine: Install coolant
reserve/overflow tank to fan shroud. Snaps into posi
tion.
(6) Install throttle cable to fan shroud.
(7) Connect negative battery cable.
NOTE: Viscous Fan Drive Fluid Pump Out Require

ment: After installing a new viscous fan drive, bring
the engine speed up to approximately 2000 rpm and
hold for approximately two minutes. This will
ensure proper fluid distribution within the drive.
COOLING SYSTEM FAN DRIVE—DIESEL ENGINE
REMOVAL
CAUTION: If the viscous fan drive is replaced

because of mechanical damage, the cooling fan
VISCOUS FAN DRIVE blades should also be inspected. Inspect for fatigue
J9307-32
cracks, loose blades, or loose rivets that could
have resulted from excessive vibration. Replace fan
Fig, 100 Fan BladeA/iscous Fan Drive—Gas
blade assembly if- any of these conditions are
Engines—Typical
found. Also inspect water pump bearing and shaft
(6) Do not unbolt fan blade assembly (Fig. 100) assembly for any related damage due to a viscous
from viscous fan drive at this time. fan drive malfunction.
(7) Remove four fan shroud-to-radiator mounting
bolts. (1) Disconnect both negative battery cables at both
(8) Remove fan shroud and fan blade/viscous fan batteries.
drive assembly as a complete unit from vehicle. (2) Remove the fan shroud mounting bolts. Posi
(9) After removing fan blade/viscous fan drive tion fan shroud towards engine.
assembly, do not place viscous fan drive in horizon
tal position. I f stored horizontally, silicone fluid in CAUTION: Do not remove the fan pulley bolts. This
the viscous fan drive could drain into its bearing pulley is under spring tension.
assembly and contaminate lubricant.
(3) The thermal viscous fan drive/fan blade assem
CAUTION: Do not remove water pump pulley-to- bly is attached (threaded) to the fan hub shaft (Fig.
water pump bolts (Fig. 68). This pulley is under 101). Remove the fan blade/fan drive assembly from
spring tension. fan pulley by turning the mounting nut clockwise (as

viewed from front). Threads on the viscous fan drive NOTE: Viscous Fan Drive Fluid Pump Out Require
are LEFT-HAND* A Snap-On 36 M M Fan Wrench ment: After installing a new viscous fan drive, bring
(number SP346 from Snap-On Cummins Diesel Tool the engine speed up to approximately 2000 rpm and
Set number 2017DSP) can be used. Place a bar or hold for approximately two minutes. This will
screwdriver between the fan pulley bolts to prevent ensure proper fluid distribution within the drive.
pulley from rotating.
THREADED
C L E A N I N G AND I N S P E C T I O N
RADIATOR CAP
INSPECTION
Hold cap at eye level, right side up. The vent valve
(Fig. 102) at bottom of cap should open. I f rubber
gasket has swollen and prevents vent valve from
opening, replace cap.
Fig. 101 Fan Blades/Viscous Fan Drive—5.9L Diesel

Fig. 102 Radiator Pressure Cap
(4) Remove the fan shroud and the fan blade/vis
cous drive as an assembly from vehicle. Hold cap at eye level, upside down. I f any light can
(5) Remove fan blade-to-viscous fan drive mount be seen between vent valve and rubber. gasket,
ing bolts. replace cap. Do not use a replacement cap that
(6) Inspect the fan for cracks, loose rivets, loose or has a spring to hold vent shut. A replacement cap
bent fan blades. must be the type designed for a coolant reserve/over
flow system with a completely sealed diaphragm
CAUTION: Some engines equipped with serpentine
spring and a rubber gasket. This gasket is used to
drive belts have reverse rotating fans and viscous
seal to radiator filler neck top surface. Use of proper
fan drives. They are marked with the word
cap will allow coolant return to radiator.
REVERSE to designate their usage. Installation of
the wrong fan or viscous fan drive can result in
RADIATOR
engine overheating.
CLEANING
INSTALLATION The radiator and air conditioning fins should be
(1) Install fan blade assembly to viscous fan drive. cleaned when an accumulation of bugs, leaves etc.
Tighten mounting bolts to 23 N-m (17 ft. lbs.) torque. has occurred. Clean radiator fins are necessary for
(2) Position the fan shroud and fan blade/viscous good heat transfer. With the engine cold, apply cold
fan drive to the vehicle as an assembly. water and compressed air to the back (engine side) of
(3) Install viscous fan drive assembly on fan hub the radiator to flush the radiator and/or A/C con
shaft. Tighten mounting nut to 57 N-m (42 ft. lbs.) denser of debris.
torque.
(4) Install fan shroud bolts. WATER PtJiVJP INSPECTION
(5) Install battery cables to batteries. Replace water pump assembly i f i t has any of the
following conditions:
• The body is cracked or damaged
7 - 62 COOLING SYSTEM _ — — — BR
CLEANING AND INSPECTION (Continued)
• Water leaks from the shaft seal. This is evident SPECIFICATIONS
by traces of coolant below the vent hole
. • Loose or rough turning bearing. Also inspect COOLANT CAPACITIES
thermal fan drive
• Impeller rubs either the pump body or timing
chain case/cover
FAN 3.9L/5.2L/5.9L 19 Liters

G a s Engines (20 Qts. or 5 . 0 G a l s . )
INSPECTION
The fan cannot be repaired. I f fan is damaged, It 8 . 0 L Engine . 2 5 Liters
must be replaced. Inspect fan as follows: ( 2 6 Q t s . or 6 . 5 G a l s . )
(1) Remove fan blade and viscous fan drive as an

5 . 9 L Diesel Engine 2 3 Liters
assembly from the engine. Refer to preceding
(24 Q t s . or 6 . 0 G a l s . )
Removal procedure.
(2) Remove fan blade assembly from viscous fan
* Nominal refill capacities a r e shown. A variation
drive unit (four bolts). m a y be observed from vehicle to vehicle due to
(3) Lay fan on a flat surface with leading edge fac manufacturing tolerances a n d refill procedures.
ing down. With tip of blade touching flat surface,
replace fan i f clearance between opposite blade and * Capacities shown include vehicles with a i r
surface is greater than 2.0 mm (.090 inch). Rocking conditioning a n d or heavy-duty cooling
motion of opposite blades-should not, exceed 2.0 mm systems.
(.090 inch). Test all blades In this manner.

J9407-2I
WARNING: DO NOT ATTEMPT TO BEND OR
STRAIGHTEN FAN BLADES IF NOT WITHIN SPECI
FICATIONS.
(4) Inspect fan assembly for cracks, bends, loose

rivets or broken welds. Replace fan i f any damage is
found.
CAUTION: If fan blade assembly is replaced

because of mechanical damage, water pump and
viscous fan drive should also be inspected. These
components could have been damaged due to
excessive vibration.
Also refer to the proceeding Viscous Fan Drive sec

tion for additional information.
SPECIFICATIONS (Continued)
TORQUE
Description Torque Description Torqy

Automatic Belt Tensioner Pulley Bolt — Radiator Mounting Bolts 11 N * m ( 9 5 in. lbs.)
3 . 9 L / 5 . 2 L / 5 . 9 L L D C G a s Engine . . . 61 N ° m ( 4 5 ft. lbs.)
Thermal Viscous Fan-to-Hub-Diesel
Automatic Belt Tensioner Pulley Bolt — Engine . . . . . . . . . . . . . . . . . . . . . 57 N«m (42 ft. lbs.)
5 . 9 L H D C G a s and 8.0L
Thermostat Housing Bolts —
V-10 Engine 8 8 N * m ( 6 5 f t . lbs.)
All G a s Engines Except 8 . 0 L V-10 . 2 3 N * m ( 2 0 0 in. lbs.)
Automatic Belt Tensioner-to-Mounting
Bracket-3.9L/5.2L/5.9L LDC
8.0LV-10. 2 5 N * m ( 2 2 0 in. lbs.)
G a s Engine 6 7 N » m ( 5 0 f t . lbs.)
Automatic Belt Tensioner-to-Mounting
Diesel Engine 2 4 N * m ( 1 8 f t . lbs.)
Bracket — 5 . 9 L H D C G a s a n d 8 . 0 L
V-10 Engines 41 N « m (30 ft. lbs.) W a t e r Pump Mounting Bolts-
A l l G a s Engines 4 0 N * m ( 3 0 ft. lbs.)
Fan Shroud-to-Radiator Mounting
Bolts 6 N » m (50 in. lbs.) W a t e r Pump Pulley Bolts —
All G a s Engines 2 2 N * m ( 1 6 f t . lbs.)
Heater Hose Fitting at Water Pump —
8 . 0 L V-10 Engine 16 N«m ( W i n . lbs.] Water Pump Mounting Bolts-
Diesel Engine 2 4 N « m (18 ft. lbs.)
Hose C l a m p s 4 N « m ( 3 4 in. lbs.)
Idler Pulley Mounting Bolt —

All G a s Engines 61 N * m (45 ft. lbs.)
J9407-20
SPECIAL TOOLS
COOLING
Pliers 6094
Pressure Tester 7700-A

BR BATTERY 8A - 1
BATTERY
CONTENTS
page page
GENERAL INFORMATION HYDROMETER TEST 5

INTRODUCTION .. 1 IGNITIONÔFF DRAW TEST 9
OVERVIEW .. 1 LOAD TEST ... 7
DESCRIPTION AND OPERATION OPEM-CiRCUiT VOLTAGE TEST 7
BATTERY MOUNTING 2 SERVICE PROCEDURES
BATTERY SIZE AND RATINGS 2 BATTERY CHARGING 10
BATTERY 2 REMOVAL AND INSTALLATION
DIAGNOSIS AND TESTING BATTERY 12
BATTERY 3 SPECIFICATIONS
BUILT-IN TEST INDICATOR . . . . . . . . . . . . . . . . 5 BATTERY 14
GENERAL INFORMATION group. This was done because the battery must be fully-
charged before any diagnosis can be performed.
OVERVIEW The factory-installed maintenance-free battery has
The battery, starting, and charging systems oper non-removable battery vent caps (Fig. 1). Water can
ate with one another, and must be tested as a com not be added to this battery. The chemical composi
plete system. In order for the vehicle to start and tion within the maintenance-free battery reduces
charge properly, all of the components involved in battery gassing and water loss at normal charge and
these systems must perform within specifications. discharge rates. Therefore, the battery should not
Group 8A covers the battery, Group 8B covers the require additional water in normal service.
starting system, and Group 8C covers the charging
system. Refer to Group 8W - Wiring Diagrams for
complete circuit descriptions and diagrams. We have
separated these systems to make i t easier to locate
the information you are seeking within this Service
Manual. However, when attempting to diagnose any
of these systems, i t is important that you keep their
inter dependency in mind.
The diagnostic procedures used in these groups
include the most basic conventional diagnostic meth
ods to the more sophisticated On-Board Diagnostics
(OBD) built into the Powertrain Control Module
(PCM). Use of a induction milliampere ammeter, volt/
ohmmeter, battery charger, carbon pile rheostat (load
tester), and 12-volt test lamp may be required.
Fig. 1 Maintenance-Free Battery
All OBD-sensed systems are monitored by the
PCM. Each monitored circuit is assigned a Diagnos If the battery electrolyte level becomes low, the
tic Trouble Code (DTC). The PCM will store a DTC in battery must be replaced. However, rapid loss of elec
electronic memory for any failure i t detects. See the trolyte can be caused by an over-charging condition.
On-Board Diagnostics Test i n Group 80 - Charging Be certain to diagnose the charging system before
System for more information. returning the vehicle to service. Refer to Group 80 -
Charging System for more information.
INTRODUCTION The factory-installed battery also has a built-in
This section covers battery diagnostic and service pro test indicator (hydrometer). The color visible in the
cedures only. For battery maintenance procedures, refer sight glass of the indicator will reveal the battery
to Group 0 - Lubrication and Maintenance. While bat condition. See Built-in Test Indicator in this group
tery charging can be considered a maintenance proce for more information.
dure, battery charging information is located in this
81 - 2 BATTERY BR
It is important that the battery, starting, and gas can collect in or around the battery. If hydrogen gas
charging systems be thoroughly tested and inspected is exposed to flame or sparks, it may ignite.
any time a battery needs to be charged or replaced. If the electrolyte level is low, the battery may arc
The cause of abnormal discharge, over-charging, or internally and explode, i f the battery is equipped with
early battery failure must be diagnosed and corrected removable cell caps, add distilled water whenever the
before a battery is replaced or returned to service. electrolyte level is below the top of the plates. If the bat
tery cell caps cannot be removed, the battery must be
replaced i f the electrolyte level becomes low.
D E S C R I P T I O N AMB O P E R A T I O N
BATTERY SIZE AND RATINGS
BATTERY The outside dimensions and terminal placement of
The storage battery is a device used to store electrical the battery conform to standards established by the
energy potential in a chemical form. When an electrical Battery Council International (BCI). Each battery is
load is applied to the battery terminals, an electrochem assigned a BCI Group Size number to help identify a
ical reaction occurs within the battery. This reaction correctly-sized replacement.
causes the battery to discharge electrical current. In addition, there are two commonly accepted
The battery is made up of six individual cells that methods for rating and comparing battery perfor
are connected in series. Each cell contains positively mance. These ratings are called Cold Cranking
charged plate groups made of lead oxide, and nega Amperage (CCA) and Reserve Capacity (RC). Both
tively charged plate groups made of sponge lead. ratings are described in more detail below.
These dissimilar metal plates are submerged in a The Group Size number, CCA rating, and RC rating
sulfuric acid and water solution called an electrolyte. can be found on the original equipment battery label.
As the battery discharges, a gradual chemical Be certain that a replacement battery has the correct
change takes place within each cell. The sulfuric acid Group Size number, as well as CCA and RC ratings that
in the electrolyte combines with the plate materials, equal or exceed the original equipment specification for
causing both plates to slowly change to lead sulfate. the vehicle being serviced. See the Battery Classifica
At the same time, oxygen from the positive plate tions and Ratings chart in Specifications at the back of
material combines with hydrogen from the sulfuric this group for more information.
acid, causing the electrolyte to become mainly water.
The chemical changes within the battery are caused COLD CRANKING AMPERAGE
by the movement of excess, or free, electrons between The Cold Cranking Amperage (CCA) rating speci
the positive and negative plate groups. This movement fies how much current (in amperes) the battery can
of electrons produces a flow of electrical current through deliver for 30 seconds at -17.7°C (0°F). Terminal volt
the load device attached to the battery terminals. age must not fall below 7.2 volts during or after the
As the plate materials become more similar chemi 30 second discharge. The CCA required is generally
cally, and the electrolyte becomes less acid, the voltage higher as engine displacement increases, depending
potential of each cell is reduced. However, by charging also upon the starter current draw requirements.
the battery with a,, voltage higher than that of the bat
tery, the battery discharging process is reversed. RESERVE CAPACITY
Charging the battery gradually changes the sul The Reserve Capacity (RC) rating specifies the
fated lead plates back into sponge lead and lead time (in minutes) i t takes for battery terminal volt
oxide, and the water back into sulfuric acid. This age to fall below 10.2 volts, at a discharge rate of 25
action restores the difference in the electron charges amperes. RC is determined with the battery fully-
deposited on the plates, and the voltage potential of charged at 26.7°C (80°F). This rating estimates how
the battery cells. long the battery might last after a charging system
For a battery to remain useful, i t must be able to failure, under minimum electrical load.
produce high-amperage current over an extended
period. A battery must also be able to accept a BATTERY MOUNTING
charge, so that its voltage potential may be restored. The battery is mounted to a molded plastic tray
in addition to producing and storing electrical energy, located in the left front corner of the engine compart
the battery serves as a capacitor, or voltage stabilizer, for ment. A U-nut is held in a formation on each side of the
a vehicle's electrical system. It absorbs most abnormal or battery tray. A holddown strap fits across the top of the
transient voltages caused by the switching of any of the battery case. A bolt passes through the holddown strap
vehicle's electrical components. on each side of the battery, and is threaded into the
The battery is vented to release excess hydrogen gas U-nut on each side of the battery tray.
that is created when the battery is being charged or dis The battery tray is fastened to the inner fender
charged. However, even with these vents, the hydrogen shield with two bolts. The tray is also fastened to the
BATTERY 8A - 3
D E S C R I P T I O N ANP O P E R A T I O N ( C o n t i n u e d !
inner wheelhouse panel. A plate with two studs TACT WITH THE SKIN, EYES, OR CLOTHING. IN
passes through the front of the tray and wheelhouse THE EVENT OF CONTACT, FLUSH WITH WATER
panel from the top. A second plate with two studs AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
passes through the rear of the tray and wheelhouse OF THE REACH OF CHILDREN.
panel from underneath. Nuts are used to secure each • IF THE BATTERY IS EQUIPPED WITH REMOV
of the four exposed studs. ABLE CELL CAPS, BE CERTAIN THAT EACH OF
Models with the diesel engine option have a second bat THE CELL CAPS IS IN PLACE AND TIGHT BEFORE
tery tray located in the right front corner of the engine THE BATTERY IS RETURNED TO SERVICE. PER
compartment. This tray, and its mounting method and SONAL INJURY AND/OR VEHICLE DAMAGE MAY
hardware, is a mirror image of the left battery tray. RESULT FROM LOOSE OR MISSING CELL CAPS.
A hole in the bottom of the left battery tray is fit
ted with a battery temperature sensor on some mod The condition of a battery is determined by two cri
els. Models without the battery temperature sensor teria:
have a plug fitted to this hole. Refer to Group 8C - 1. State-Of-Charge - This can be determined by
Charging System for more information on the battery viewing the built-in test indicator, by checking the spe
temperature sensor. cific gravity of the electrolyte (hydrometer test), or by
Models with an optional vehicle speed control sys checking the battery voltage (open circuit voltage test).
tem have the speed control servo mounting bracket 2. Cranking Capacity - This can be determined by
attached to the bottom of the left battery tray. Refer performing a battery load test, which measures the abil
to Group 8H - Vehicle Speed Control System for more ity of the battery to supply high-amperage current.
information. First, determine the battery state-of-charge. This
can be done in one of three ways. I f the battery has a
built-in test indicator, use this test to determine the
DIAGNOSIS AND TESTING state-of-charge. I f the battery has no test indicator,
but has removable cell caps, perform the hydrometer
BATTERY test to determine the state-of-charge. I f the cell caps
The battery must be completely charged and the top, are not removable, or a hydrometer is not available,
posts, and terminal clamps should be properly cleaned perform the open circuit voltage test to determine the
before diagnostic procedures are performed. See Battery state-of-charge.
Charging in this group for more information. The battery must be charged before proceeding
with a load test if:
NOTE; Models equipped with the diesel engine option • The built-in test indicator has a black or dark
are equipped with two 12-volt batteries, connected in color visible.
parallel (positive-to-positive/negative-to-negative). The • The temperature corrected specific gravity is
secondary battery, on the passenger's side, is dedi less than 1.235.
cated to providing current for the operation of the • The open circuit voltage is less than 12.4 volts.
intake manifold air heater. The primary battery, on the A battery that will not accept a charge is faulty,
driver's side, is dedicated to all other vehicle electrical and must be replaced. Further testing is not
requirements. In order to ensure accurate diagnostic required. A fully-charged battery must be load tested
results, these batteries MUST be disconnected from to determine its cranking capacity. A battery that is
each other, as well as from the vehicle electrical sys fully-charged, but does not pass the load test, is
tem, when being tested. faulty and must be replaced.
NOTE: Completely discharged batteries may take

WARNING:
several hours to accept a charge. See Charging A
• IF THE BATTERY SHOWS SIGNS OF FREEZ
Completely Discharged Battery in this group for
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO
more information.
LYTE LEVEL, DO NOT TEST, ASSIST BOOST, OR
CHARGE. THE BATTERY MAY ARC INTERNALLY A battery is fully-charged when:
AND EXPLODE. PERSONAL INJURY AND/OR VEHI • All cells are gassing freely during charging.
CLE DAMAGE MAY RESULT. • A green color is visible in the sight glass of the
• EXPLOSIVE HYDROGEN GAS FORMS IN AND built-in test indicator.
AROUND THE BATTERY DO NOT SMOKE, USE FLAME, • Three corrected specific gravity tests, taken at 1-hour
OR CREATE SPARKS NEAR THE BATTERY. PERSONAL intervals, indicate no increase in the specific gravity.
INJURY AND/OR VEHICLE DAMAGE MAY RESULT. • Open circuit voltage is 12.4 volts or greater.
• THE BATTERY CONTAINS SULFURIC ACID,
WHICH IS POISONOUS AND CAUSTIC. AVOID CON
8A - 4 BATTERY — BR
IS THIS THE C O R R E C T
BATTERY YES BATTERY FOR THIS R E P L A C E WITH
NO
S E E M S WEAK V E H I C L E ? R E F E R TO CORRECT
OR DEAD? SPECIFICATIONS, BATTERY.
IN THIS GROUP.
YES
A R E BATTERY
POSTS TIGHT AMD HO REPLACE
IS BATTERY C A S E DAMAGED
F R E E OF DAMAGE BATTERY.
OR L E A K S ?
YES
A R E BATTERY
NO CLEAN AND
CONNECTIONS
TIGHTEN AS
CLEAN AND
REQUIRED.
TIGHT?
DONE
YES
IS BATTERY FULLY
C H A R G E BATTERY.
C H A R G E D ? R E F E R TO
DOES BATTERY A C C E P T NO REPLACE
T E S T INDICATOR, NO A C H A R G E ? R E F E R TO FAILED
HYDROMETER TEST, OR
BATTERY CHARGING, BATTERY.
OPEN CIRCUIT VOLTAGE
IN THIS GROUP.
TEST, IN THIS GROUP.
YES
YES
WILL BATTERY
PASS A LOAD NO
T E S T ? R E F E R TO
LOAD TEST, IN
THIS GROUP.
YES
I R E F E R TO
BATTERY STILL ABNORMAL
NO
S E E M S WEAK OR BATTERY
DEAD WHEN DISCHARGING,
STARTING? IN THIS GROUP.
YES
R E F E R TO
GROUP8B -
STARTING S Y S T E M
Battery Diagnosis
BR BATTERY 8A - 5
DIAGNOSIS AND TESTING (Continued!

ABNORMAL BATTERY DISCHARGING • THE BATTERY CONTAINS SULFURIC ACID,
Any of the following- conditions can result in abnor WHICH IS POISONOUS AND CAUSTIC. AVOID CON
mal battery discharging: TACT WITH THE SKIN, EYES, OR CLOTHING. IN
1. Corroded or loose- battery posts and terminal THE EVENT OF CONTACT, FLUSH WITH WATER
clamps. AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
2. A loose or worn generator drive belt. OF THE REACH OF CHILDREN.
3. Electrical loads that exceed the output of the • IF THE BATTERY IS EQUIPPED WITH REMOV
charging system. This can be due to equipment ABLE CELL CAPS, BE CERTAIN THAT EACH OF
installed after manufacture, or repeated short trip THE CELL CAPS IS IN PLACE AND TIGHT BEFORE
use. THE BATTERY IS RETURNED'TO SERVICE. PER
4. Slow driving speeds (heavy traffic conditions) or SONAL INJURY AND/OR VEHICLE DAMAGE MAY
prolonged idling, with high-amperage draw systems RESULT FROM LOOSE OR MISSING CELL CAPS.
in use.
5. A faulty circuit or component causing excessive Before testing, visually inspect the battery for any
ignition-off draw. See Ignition-Off Draw Test in this damage (a cracked case or cover, loose posts, etc.)
group for more information. that would cause the battery to be faulty. In order to
6. A faulty or incorrect charging system compo obtain correct indications from the built-in test indi
nent. cator, it is important that the battery be level and
7. A faulty or incorrect battery. have a clean sight glass. Additional light may be
required to view the indicator. Do not use open
BUILT-IN TEST INDICATOR flame as a source of additional light.
A test indicator (hydrometer) built into the top of To read the built-in test indicator, look into the
the battery case provides visual information for bat sight glass and note the color of the indicator (Fig. 3).
tery testing (Fig. 2). Like a hydrometer, the built-in Refer to the following description, as the color indi
test indicator measures the specific gravity of the cates:
electrolyte. The test indicator reveals the battery • Green - indicates 75% to 100% state-of-charge.
state-of-charge; however, i t will not reveal the crank The battery is adequately charged for further testing
ing capacity of the battery. A load test must be per or return to use. I f the vehicle will not crank for a
formed to determine the battery cranking capacity. minimum of 15 seconds with a fully-charged battery,
See Load Test in this group for more information. perform the Load Test.
• Black or Dark - indicates 0% to 75% state-of-
charge. The battery is inadequately charged and
must be charged until a green indication is visible in
the sight glass (12.4 volts or more), before the bat
tery is tested further or returned to service. See Bat
tery Charging in this group for more information.
Also see Abnormal Battery Discharging in this group
for possible causes of the discharged condition.
• Yellow or Bright - indicates a low electrolyte
level. The electrolyte level in the battery is below the
test indicator. A maintenance-free battery with non
removable cell caps must be replaced i f the electro
Fig. 2 Built-in Test Indicator lyte level is low. Water must be added to a low-
maintenance battery with removable cell caps before
WARNING; it is charged. See Battery Charging in this group for
• IF THE BATTERY SHOWS SIGNS OF FREEZ more information. A low electrolyte level may be
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO caused by an over-charging condition. Refer to Group
LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR 8C - Charging System to diagnose an over-charging
CHARGE. THE BATTERY MAY ARC INTERNALLY condition.
AND EXPLODE. PERSONAL INJURY AND/OR VEHI
CLE DAMAGE MAY RESULT HYDROMETER TEST
• EXPLOSIVE HYDROGEN GAS FORMS IN AND The hydrometer test reveals the battery state-of-
AROUND THE BATTERY. DO NOT SMOKE, USE charge by measuring the specific gravity of the elec
FLAME, OR CREATE SPARKS NEAR THE BATTERY. trolyte. This test cannot be performed on
PERSONAL INJURY AND/OR VEHICLE DAMAGE maintenance-free batteries with non-removable cell
MAY RESULT. caps. I f the battery has non-removable cell caps, see
8A - 6 BATTERY BR
Add distilled water i f the electrolyte level is below
TEST INDICATOR/STATE-OF-CHARGE
the top of the battery plates.
LOW Refer to the hydrometer manufacturer's instruc
100% 75% O
ELECTROLYTE
tions for correct use of the hydrometer. Remove only
enough electrolyte from the battery so that the float
®
is off the bottom of the hydrometer barrel with pres
(^) (^^^^^ sure on the bulb released.
CAUTION: Exercise care when inserting the tip of

GREEN BLACK YELLOW the hydrometer into a cell to avoid damaging the
J958A-6 plate separators. Damaged plate separators can
cause early battery failure.
Fig. 3 Buiit-ln Test Indicator Sight Glass
Built-in Test Indicator or Open Circuit Voltage Test To read the hydrometer correctly, hold i t with the
in this group. top surface of the electrolyte at eye level. Hydrometer
floats are generally calibrated to indicate the specific
Specific gravity is a comparison of the - density of
gravity correctly only at 26.7°C (80°F). When testing
the electrolyte to the density of pure water. Pure
the specific gravity at any other temperature, a cor
water has a specific gravity of 1.000, and sulfuric
rection factor is required.
acid has a specific gravity of 1.835. Sulfuric acid
makes up approximately 35% of the electrolyte by The correction factor is approximately a specific
weight, or 24% by volume. gravity value of 0.004, referred to as 4 points of spe
cific gravity. For each 5.5°C above 26.7°C (10°F above
In a fully-charged battery the electrolyte will have
80°F), add 4 points. For each 5.5°C below 26.7°C
a temperature-corrected specific gravity of 1.260 to
(10°F below 80°F), subtract 4 points. Always correct
1.290. However, a specific gravity of 1.235 or above is
the specific gravity for temperature variation. Test
satisfactory for battery load testing and/or return to
the specific gravity of the electrolyte in each battery
service.
cell.
WARNING: EXAMPLE: A battery is tested at -12.2°C (10°F)
• IF THE BATTERY SHOWS SIGNS OF FREEZ and has a specific gravity of 1.240. Determine the
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO actual specific gravity as follows:
LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR (1) Determine the number of degrees above or
CHARGE. THE BATTERY MAY ARC INTERNALLY below 26.7°C (80°F):
AND EXPLODE. PERSONAL INJURY AND/OR VEHI 26.6°C - -12.2°C = 38.8°C (80°F - 10°F =
CLE DAMAGE MAY RESULT. 70°F)
• EXPLOSIVE HYDROGEN GAS FORMS IN AND (2) Divide the result from Step 1 b y 5.5 (10):
AROUND THE BATTERY. DO NOT SMOKE, USE 38.8°C/5.5 = 7 (70°F/10 = 7)
FLAME, OR CREATE SPARKS NEAR THE BATTERY. (3) Multiply the result from Step 2 by the temper
PERSONAL INJURY AND/OR VEHICLE DAMAGE ature correction factor (0.004):
MAY RESULT. 7 X 0 . 004 = 0 .028
• THE BATTERY CONTAINS SULFURIC ACID, (4) The temperature at testing was below 26.7°C
WHICH IS POISONOUS AND CAUSTIC. AVOID CON (80°F); therefore, the temperature correction factor is
TACT WITH THE SKIN, EYES, OR CLOTHING. IN subtracted:
THE EVENT OF CONTACT, FLUSH WITH WATER 1.240 - 0.028 = 1.212
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT The corrected specific gravity of the battery in this
OF THE REACH OF CHILDREN. example is 1.212.
• IF THE BATTERY IS EQUIPPED WITH REMOV I f the specific gravity of all cells is above 1.235, but
ABLE CELL CAPS, BE CERTAIN THAT EACH OF the variation between cells is more than 50 points
THE CELL CAPS IS IN PLACE AND TIGHT BEFORE (0.050), the battery should be replaced. I f the specific
THE BATTERY IS RETURNED TO SERVICE. PER gravity of one or more cells is less than 1.235, charge
SONAL INJURY AND/OR VEHICLE DAMAGE MAY the battery at a rate of approximately 5 amperes.
RESULT FROM LOOSE OR MISSING CELL CAPS, Continue charging until three consecutive specific
gravity tests, taken at 1-hour intervals, are constant.
Before testing, visually inspect the battery for any If the cell specific gravity variation is more than 50
damage (a cracked case or cover, loose posts, etc.) points (0.050) at the end of the charge period, replace
that would cause the battery to be faulty. Then the battery.
remove the cell caps and check the electrolyte level. When the specific gravity of all cells is above 1.235,
and the cell variation is less than 50 points (0.050),
BR BATTERY 8A - 7
the battery may be load tested to determine its (2) Disconnect and isolate both battery cables, neg
cranking capacity. See Load Test in this group for ative cable first.
more information. (3) Using a voltmeter connected to the battery
posts (refer to the instructions provided with the
OPEN-CIRCUIT VOLTAGE TEST voltmeter), measure the open-circuit voltage (Fig. 4).
A battery open-circuit voltage (no load) test will
show the state-of-charge of a battery. This test can be
used in place of the hydrometer test, i f a hydrometer
is not available; or, for maintenance-free batteries
with non-removable cell caps.
WARNING:
• IF THE BATTERY SHOWS SIGNS OF FREEZ
LYTE LEVEL, DO NOT TEST, ASSIST BOOST, OR
CHARGE. THE BATTERY MAY ARC INTERNALLY
CLE DAMAGE MAY RESULT.
• EXPLOSIVE HYDROGEN GAS FORMS IN AND
898A-7
AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY. Fig. 4 Testing Open-Circuit Voltage
PERSONAL INJURY AND/OR VEHICLE DAMAGE
MAY RESULT. See the Open-Circuit Voltage chart. This voltage
• THE BATTERY CONTAINS SULFURIC ACID, reading will indicate the battery state-of-charge, but
WHICH IS POISONOUS AND CAUSTIC. AVOID CON will not reveal its cranking capacity. I f a battery has
TACT WITH THE SKIN, EYES, OR CLOTHING. IN an open-circuit voltage reading of 12.4 volts or
THE EVENT OF CONTACT, FLUSH WITH WATER greater, it may be load tested to reveal its cranking
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT capacity. See Load Test in this group for more infor
OF THE REACH OF CHILDREN. mation.
• IF THE BATTERY IS EQUIPPED WITH REMOV
Open Circuit Voltage
ABLE CELL CAPS, BE CERTAIN THAT EACH OF
THE CELL CAPS IS IN PLACE AND TIGHT BEFORE Open Circuit Volts Charge Percentage
THE BATTERY IS RETURNED TO SERVICE. PER 11.7 volts or less 0%
SONAL INJURY AND/OR VEHICLE DAMAGE MAY
RESULT FROM LOOSE OR MISSING CELL CAPS. 12.0 volts 25%
12.2 volts 50%
Before proceeding with this test, completely charge 12.4 volts 75%
the battery as described in Battery Charging in this
group. 12.6 volts or more 100%
(1) Before measuring the open-circuit voltage, the
surface charge must be removed from the battery. LOAD TEST
Turn the headlamps on for 15 seconds, then allow up A battery load test will verify the battery cranking
to five minutes for the battery voltage to stabilize. capacity. The test is based on the Cold Cranking
Amperage (CCA) rating of the battery. See the Bat
NOTE: Models equipped with the diesel engine tery Classifications and Ratings chart in Specifica
option are equipped with two 12-volt batteries, con tions at the back of this group.
nected in parallel (positive-to-positive/negative-to-
negative). The secondary battery, on the
passenger's side, is dedicated to providing current
for the operation of the intake manifold air heater.
The primary battery, on the driver's side, is dedi
cated to all other vehicle electrical requirements. In
order to ensure accurate diagnostic results, these
batteries MUST be disconnected from each other,
as well as from the vehicle electrical system, when
being tested.
8A - 8 BATTERY
DIAGNOSIS mm T E S T I N G (Continuedl
WARNING;
• IF THE BATTERY SHOWS SIGNS OF FREEZ II
LYTE LEVEL, DO NOT TEST, ASSIST BOOST, OR 1
1 - — —-1— -- ii
CLE DAMAGE MAY RESULT. . ,_ . j

• EXPLOSIVE HYDROGEN GAS FORMS IN AND
AROUND THE BATTERY. DO NOT SMOKE, USE •
FLAME, OR CREATE SPARKS NEAR THE BATTERY. ?*/ V
mm OL
T
S V -
1
"^X^v.''.
PERSONAL INJURY AND/OR VEHICLE DAMAGE
MAY* RESULT. --6./ V 1 '.• •/
3
• THE BATTERY CONTAINS SULFURIC ACID,

WHICH IS POISONOUS AND CAUSTIC. AVOID CON _ -.——i - i & ' f p I p 'ilp.
TACT WITH THE SKIN, EYES, OR CLOTHING. IN
THE EVENT OF CONTACT, FLUSH WITH WATER Fig. 5 Volt-Ammeter-Load Tester - Typical
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.
• IF THE BATTERY IS EQUIPPED WITH REMOV
ABLE CELL CAPS, BE CERTAIN THAT EACH OF
THE CELL CAPS IS IN PLACE AND TIGHT BEFORE
THE BATTERY IS RETURNED TO SERVICE. PER
RESULT FROM LOOSE OR MISSING CELL CAPS.
Before proceeding with this test, completely charge

the battery as described in Battery Charging i n this
group.
NOTE: Models equipped with the diesel engine J948A-13

option are equipped with two 12-volt batteries, con
nected in parallel (positive-to-positive/negative-to- Fig. 6 Volt-Ammeier-Load Tester Connections
negative). The secondary battery, on the
passenger's side, is dedicated to providing current
ii ;
for the operation of the intake manifold air heater.
The primary battery, on the driver's side, is dedi
!i
cated to all other vehicle electrical requirements. In
order to ensure accurate diagnostic results, these
| j ^ - r ^ ^ : v : i W : i! : :
11
batteries MUST be disconnected from each other,
it
as well as from the vehicle electrical system, when
being tested. ! 1 .-._,s3f^-i' " -J •— 1 i
(1) Disconnect and isolate both battery cables, neg
; ? y'C >—
U j / ^ vo
ative cable first. The battery top and posts should be
clean. j ^ ^ II; i
(2) Connect a suitable volt-ammeter-load tester
(Fig. 5) to the battery posts (Fig. 6). Refer to the j VOL'-su
rco
rnrajasn^crc^=™
SIL^±2£L jl j
operating instructions provided with the tester being Fig. 7 Remove Surface Charge from Battery
used. Check the open-circuit voltage (no load) of the
battery. Open-circuit voltage must be 12.4 volts or (4) Allow the battery to stabilize to open-circuit
greater. voltage. I t may take up to five minutes for the bat
(3) Rotate the load control knob (carbon pile rheo tery voltage to stabilize.
stat) to apply a 300 amp load to the battery for 15 (5) Rotate the load control knob to maintain a load
seconds, then return the control knob to the Off posi equal to 50% of the battery's CCA rating (Fig. 8).
tion (Fig. 7). This will remove the surface charge After 15 seconds, record the loaded voltage reading,
from the battery. then return the load control knob to the Off position.
BR BATTERY 8A - 9
DIAGNOSIS mm
A vehicle that has not been operated for approxi
mately 20 days, may discharge the battery to an
inadequate level. When a vehicle will not be used for
20 days or more (stored), remove the IOD fuse from
the fuseblock module. This will reduce battery dis
charging.
Excessive IOD can be caused by:
• Electrical items left on
• Faulty or improperly adjusted switches
• An internally shorted generator
• Intermittent shorts in the wiring.
I f the IOD is over 20 milliamperes, the problem
must be found and corrected before replacing a bat
898A-11 tery. I n most cases, the battery can be charged and
returned to service.
Fig. 8 Load 50% CCA Rating - Note Voltage
(6) The voltage drop will vary with the battery DIAGNOSIS
temperature at the time of the load test. The battery
CAUTION: Testing for high-amperage IOD must be
temperature can be estimated by the ambient tem
performed first to prevent damage to most milliam-
perature during the past several hours. I f the battery
pere meters.
has been charged, boosted, or loaded a few minutes
prior to test, the battery will be somewhat warmer.
See the Load Test Temperature chart for the proper NOTE: When testing a diesel engine-equipped vehi
loaded voltage reading. cle (dual batteries), do not check the IOD between
batteries. One battery may be at a higher state-of-
Load Test Temperature charge than the other, which will cause a high IOD
Minimum Volt Temperature between the batteries. Remove the negative cable
from the passenger's side battery negative terminal
age °F °c post prior to performing the IOD diagnosis outlined
9.6 volts 70° and above 21° and above below.
9.5 volts 60° 16°
(1) Verify that all electrical accessories are off.
9.4 volts 50° 10° Turn off all lamps, remove the ignition key, and close
C
9.3 volts 40° 4 all doors. I f the vehicle is equipped with a illumi
9.1 volts 30° -1° nated entry system or electronically tuned radio,
allow the electronic timer function of these systems
8.9 volts 20° -7°
to automatically shut off (time out). This may take
8.7 volts 10° -12° up to three minutes.
8.5 volts 0° -18° (2) Determine that the underhood lamp is operat
ing properly, then disconnect the lamp or remove the
bulb.
(7) I f the voltmeter reading falls below 9.6 volts, at (3) Disconnect the battery negative cable.
a minimum battery temperature of 21°C (70°F), the (4) Connect a typical 12-volt test lamp (low-watt
battery is faulty and must be replaced. age bulb) between the disconnected battery negative
cable clamp and the battery negative terminal post.
IGNITI0N-0FF DRAW TEST Make sure that the doors remain closed so that the
Ignition-Off Draw (IOD) refers to power being illuminated entry system is not activated. The test
drained from the battery with the ignition switch in lamp may light brightly for up to three minutes, or
the Off position. A normal vehicle electrical system may not light at all, depending upon the vehicle's
will draw from 5 to 20 milliamperes (0.005 - 0.020 electrical equipment. The term "brightly," as used
ampere) with the ignition switch in the Off position, throughout the following tests, implies the brightness
and all non-ignition controlled circuits . in proper of the test lamp will be the same as i f i t were con
working order. The 20 milliamperes are needed to nected across the battery. The test lamp must be
supply Powertrain Control Module (PCM) memory, securely clamped to the battery negative cable clamp
digital clock memory, and electronically tuned radio and the battery negative terminal post. I f the conti
memory. nuity between the battery negative terminal post and
8A-10 BATTERY

cable clamp is lost during any part of the IOD test, AND EXPLODE. PERSONAL INJURY AND/OR VEHI
the electronic timer function will be activated and all CLE DAMAGE MAY RESULT.
tests must be repeated. • EXPLOSIVE HYDROGEN GAS FORMS IN AND
(5) After three minutes, the test lamp should turn AROUND THE BATTERY DO NOT SMOKE, USE
off or be dimly lit, depending upon the vehicle's elec FLAME, OR CREATE SPARKS NEAR THE BATTERY.
trical equipment. I f the test lamp remains brightly PERSONAL INJURY AND/OR VEHICLE DAMAGE
lit, do not disconnect it. Remove each fuse or circuit MAY RESULT.
breaker (refer to Group 8W - Wiring Diagrams for • THE BATTERY CONTAINS SULFURIC ACID,
more information) until the test lamp is either off, or WHICH IS POISONOUS AND CAUSTIC. AVOID CON
dimly lit. This will Isolate each circuit and Identify TACT WITH THE SKIN, EYES, OR CLOTHING. IN
the source of the high-amperage IOD. I f the test THE EVENT OF CONTACT, FLUSH WITH WATER
lamp is still brightly lit after disconnecting each fuse AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
and circuit breaker, disconnect the wiring harness OF THE REACH OF CHILDREN.
from the generator. I f the test lamp now turns off or • IF THE BATTERY IS EQUIPPED WITH REMOV
Is dimly lit, refer to Group 8C - Charging System to ABLE CELL CAPS, BE CERTAIN THAT EACH OF
diagnose the faulty charging system. Do not discon THE CELL CAPS IS IN PLACE AND TIGHT BEFORE
nect the test lamp. After the high-amperage IOD has THE BATTERY IS RETURNED TO SERVICE. PER
been corrected, the low-amperage IOD may be SONAL INJURY AND/OR VEHICLE DAMAGE MAY
checked; I t is now safe to install a milliampere meter RESULT FROM LOOSE OR MISSING CELL CAPS.
to check the low-amperage IOD.
(6) With the test lamp still connected securely,
clamp a milliampere meter between the battery neg CAUTION:
ative terminal post and the negative cable clamp. ® Always disconnect and isolate the battery neg
ative cable before charging a battery. Do not exceed
CAUTION: Do not open any doors, or turn on any 16.0 volts while charging a battery. Damage to the
electrical accessories, with the test lamp discon vehicle electrical system components may result.
nected or the milliampere meter may be damaged. • Battery electrolyte will bubble inside the bat
tery case during normal battery charging. Electro
(7) Disconnect the test lamp.-Observe the milliam lyte boiling or being discharged from the battery
pere meter. The current draw should mot exceed 20 vents indicates a battery over-charging condition.
milliamperes (0.020 ampere). I f draw exceeds 20 mil Immediately reduce the charging rate or turn off the
liamperes, isolate each circuit by removing the circuit charger to evaluate the battery condition. Damage
breakers and fuses. The milliampere meter reading to the battery may result from over-charging.
will drop when the source of the draw is discon • The battery should not be hot to the touch. If
nected. Repair this circuit as required, whether it is the battery feels hot to the touch, turn off the
a wiring short, incorrect switch adjustment, or a charger and let the battery cool before continuing
component failure. the charging operation. Damage to the battery may
result.
SERVICE PROCEDURES
NOTE: Models equipped with the diesel engine
BATTERY CHARGING option are equipped with two 12-volt batteries, con
A battery is fully-charged when: nected in parallel (positive-to-positive/negative-to-
• A l l cells are gassing freely during battery charg negative). The secondary battery, on the
ing. passenger's side, is dedicated to providing current
• A green color is visible in the sight glass of the for the operation of the intake manifold air heater.
built-in test indicator. The primary battery, on the driver's side, is dedi
• Three corrected specific gravity tests, taken at cated to all other vehicle electrical requirements. In
1-hour intervals, indicate no increase in the specific order to ensure proper charging of each battery,
gravity. these batteries MUST be disconnected from each
other, as well as from the vehicle electrical system,
• Open-circuit voltage is 12.4 volts or above. while being charged.
WARNING: Some battery chargers are equipped with polarity-
• SF THE BATTERY SHOWS SIGNS OF FREEZ sensing circuitry. This circuitry protects the charger
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO and/or battery from being damaged i f they are
LYTE LEVEL, DO NOT TEST, ASSIST BOOST, OR improperly connected. I f the battery state-of-charge
BR BATTERY 8A -11
is too low for the polarity-sensing circuitry to detect, . (3) Battery chargers vary in the amount of voltage
the charger will not operate. This makes It appear and current they provide. The amount of time
that the battery will not accept charging current. required for a battery to accept measurable charger
Refer to the Instructions provided with the battery current at various voltages is shown i n the Charge
charger to bypass the polarity-sensing circuitry. Rate chart. I f the charge current is still not measur
After the battery has been charged to 12.4 volts or able at end of the charging time, the battery is faulty
greater, perform a load test to determine the battery and must be replaced. I f the charge current is mea
cranking capacity. I f the battery will endure a load surable during the charging time, the battery may be
test, return the battery to use. I f the battery will not good and the charging should be completed in the
endure a load test,' i t Is faulty and must be replaced. normal manner.
Clean and inspect the battery holddowns, tray, ter
minals, posts, and top before completing service. See Charge Rate
the Battery Removal and installation procedures In Voltage Hours
this group for more information.
16.0 volts maximum up to 4 hours
CHARGING A COMPLETELY DISCHARGED 14.0 to 15.9 volts up to 8 hours
BATTERY 13.9 volts or less up to 16 hours
The following procedure should be used to recharge
a completely discharged battery. Unless this proce CHARGING TIME REQUIRED
dure is properly followed, a good battery may be The time required to charge a battery will vary,
needlessly replaced. depending upon the following factors:
(1) Measure the voltage at the battery posts with a • Battery Capacity - A completely discharged
voltmeter, accurate to 1/10 (0.10) volt (Fig. 9). I f the heavy-duty battery requires twice the charging time
reading is below 10 volts, the charge current will be of a small capacity battery.
low. I t could take some time before the battery • Temperature - A longer time will be needed to
accepts a current greater than a few milliamperes. charge a battery at -18°C (0°F) than at 27°C (80°F).
Such low current may not be detectable on the When a fast charger is connected to a cold battery,
ammeters built into many chargers. the current accepted by the battery will be very low
at first. As the battery warms, i t will accept a higher
charging current rate (amperage).
• Charger Capacity - A charger that supplies
only 5 amperes will require a longer charging time. A
charger that supplies 20 amperes or more will
require a shorter charging time.
• State-Of-Charge - A completely discharged bat
tery requires more charging time than a partially
discharged battery. Electrolyte is nearly pure water
in a completely discharged battery. At first, the
charging current (amperage) will be low. As the bat
tery charges, the specific gravity of the electrolyte
will gradually rise..
898A-12
Battery Charging Timetable
Fig. 9 Voltmeter Accurate to 1/10 Volt Connected
Charging 5 10 20
(2) Disconnect and isolate the battery negative Amperage Amperes Amperes Ampere
cable. Connect the battery charger leads. Some bat
tery chargers are equipped with polarity-sensing cir Open Circuit
Hours Charging at 21 °C (70°F)
cuitry. This circuitry protects the charger and/or Voltage
battery from being damaged i f they are improperly 12.25 to 12.39 6 hours 3 hours ' 1.5 hours
connected. I f the battery state-of-charge is too low for
12.00 to 12.24 8 hours 4 hours 2 hours
the polarity-sensing circuitry to detect, the charger
will not operate. This makes it appear that the bat 11.95 to 11.99 12 hours 6 hours 3 hours
tery will not accept charging current. Refer to the 10.00 to 11.94 14 hours 7 hours 3.5 hours
instructions provided with the battery charger to less than 10.00 See Charging Completely
bypass the polarity-sensing circuitry. Discharged Battery
8A - 12 BATTERY BR
WARNING: NEVER EXCEED 20 AMPS WHEN

CHARGING A COLD (-1°C/30°F) BATTERY. THE BAT
TERY MAY ARC INTERNALLY AND EXPLODE. PER
RESULT.
R E M O V A L AND I N S T A L L A T I O N
BATTERY
(1) Turn the ignition switch to the Off position.
Make sure all electrical accessories are off.
(2) Loosen the cable terminal clamps and discon
nect both battery cables, negative cable first. I f nec
essary use a puller to remove the terminal clamps
from the battery posts (Fig. 10).
BATTERY
ERMINA
PULLER
Fig. 11 Clean Battery Cable Terminal Clamp
BATTERY
BATTERY
898A-4
Fig. 10 Remove Battery Terminal Clamp

(3) Inspect the cable terminal clamps for corrosion
and damage. Remove any corrosion using a wire
brush or a post and terminal cleaning tool, and a
sodium bicarbonate (baking soda) and warm water
cleaning solution (Fig. 11). Replace any cable that
has damaged or deformed terminal clamps.
WARNING: WEAR A SUITABLE PAIR OF RUBBER

GLOVES (NOT THE HOUSEHOLD TYPE) WHEN
REMOVING A BATTERY BY HAND. SAFETY
GLASSES SHOULD ALSO BE WORN. IF THE BAT
TERY IS CRACKED OR LEAKING, THE ELECTRO
LYTE CAN BURN THE SKIN AND EYES.
(4) Remove the battery holddowns and remove the

battery from the vehicle (Fig. 12) or (Fig. 13).
(5) Inspect the battery tray and the holddowns for
corrosion or damage (Fig. 14), (Fig. 15) or (Fig. 16).
Remove any corrosion using a wire brush and a
sodium bicarbonate (baking soda) and warm water
cleaning solution. Paint any exposed bare metal and
replace any damaged parts. 8056d9f6
Fig. 12 Left Battery Holddown

BR • _ _ — _ — — BATTElf 8A - 1 3
Fig. 13 Right Battery Holddown - Diesel Engine
Fig. 16 Right Battery Tray - Diesel Engine

cleaning solution does not enter the battery cells
through the vent holes. I f the battery is being
replaced, see the Battery Ratings and Classifications
chart in Specifications at the back of this group. Con
Fig. 14 Left Battery Tray - w/o Speed Control firm that the replacement battery is the correct size
(6) Inspect the battery case for cracks or other and has the correct ratings for the vehicle.
damage that could result in electrolyte leaks. Also, (9) Clean any corrosion from the battery terminal
check the battery terminal posts for looseness. Bat posts with a wire brush or a post and terminal
teries with damaged cases or loose posts must be cleaner, and a sodium bicarbonate (baking soda) and
replaced. warm water cleaning solution (Fig. 18).
(7) Inspect the battery built-in test indicator sight (10) Position the battery in the tray. Ensure that
glass for an indication of the battery condition. I f the the positive and negative terminal posts are correctly
electrolyte level is low, the battery must be replaced. positioned. The cable terminal clamps must reach the
I f the battery is discharged, charge as required. See correct battery post without stretching the cables
Built-in Test Indicator and Battery Charging in this (Fig. 19).
group for more information. (11) Loosely install the battery holddown hard
(8) If the battery is to be reinstalled, clean the out ware. Ensure that the battery base is correctly posi
side of the battery case and the top cover with a tioned in the tray, then tighten the holddowns to 12
sodium bicarbonate (baking soda) and warm water N-m (100 in. lbs.).
cleaning solution to remove any acid film (Fig. 17).
Rinse the battery with clean water. Ensure that the
8A-14 BATTERY 3R
REMOVAL AND II ION (Continued)
C L E A N I N G BRUSH POSITIVE
CABLE
TEST
INDICATOR WARM WATER
AND BAKING
S O D A SOLUTION
BATTERY
TEST INDICATOR J908B-8
Fig. 19 Battery Cables - Typical

CAUTION: Be certain that the battery cables are
connected to the correct battery terminals. Reverse
polarity may damage electrical components.
(12) Place an oiled felt washer on the battery pos

itive terminal post.
BATTERY RK108
(13) Install and tighten the battery positive cable
Fig. 17 Clean Battery
terminal clamp. Then install and tighten the nega
tive cable terminal clamp. Tighten both cable termi
nal clamp bolts to 8.5 N-m (75 in. lbs.).
(14) Apply a thin coating of petroleum jelly or
chassis grease to the exposed surfaces of the cable
TERMINAL terminal clamps and battery terminal posts.
BRUSH
SPECIFICATIONS
BATTERY
Battery Classifications and Ratings

BCI Group Cold Load
Reserve
Size Cranking Test
Capacity
Classification Amperage Amperage
120
27 600 300
Minutes
150
27 750 375
Minutes
J928B-30
Fig. 18 Clean Battery Terminal Post

BR STARTING SYSTEMS 81 - 1
STARTING SYSTEMS
CONTENTS
page page
GENERAL INFORMATION CONTROL CIRCUIT TESTS 6

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1 FEED CIRCUIT TESTS 4
OVERVIEW 1 STARTING SYSTEM 2
DESCRIPTION AND OPERATION . IE10VAL AND INSTALLATION
STARTER RELAY 2 STARTER RELAY 10
STARTER 2 STARTER 8
STARTING SYSTEM 1 SPECIFICATIONS
DIAGNOSIS AND TESTING STARTING SYSTEM 10
COLD CRANKING TEST 4
GENERAL I N F O R M A T I O N © Clutch pedal position switch (manual transmission)

• Park/neutral position switch (automatic trans
OVERVIEW mission)
The battery, starting, and charging systems oper • Wiring harness and connections.
ate with one another, and must be tested as a com This group covers diagnosis of the complete start
plete system. In order for the vehicle to start and ing system, except the battery. However, this group
charge properly, all of the components involved in only covers service procedures for the starter and
these systems must perform within specifications. starter relay. Service procedures for other starting
Group 8A covers the battery, Group 8B covers the system components can be located as follows:
starting system, and Group 8C covers the charging • Battery - refer to Group 8A - Battery for the
system. Refer to Group 8W - Wiring Diagrams for diagnostic and service procedures
complete circuit descriptions and diagrams. We have • Ignition switch - refer to Group 8D - Ignition
separated these systems to make i t easier to locate Systems for the service procedures
the information you are seeking within this Service • Clutch pedal position switch - refer to Group 6 -
Manual. However, when attempting to diagnose any Clutch for the service procedures
of these systems, it is important that you keep their • Park/neutral position switch - refer to Group 21
interdependency in mind. - Transmission for the service procedures
The diagnostic procedures used in these groups • Wiring harness and connections - refer to Group
include the most basic conventional diagnostic meth 8W - Wiring Diagrams for the service procedures.
ods to the more sophisticated On-Board Diagnostics
(OBD) built into the Powertrain Control Module DESCRIPTION AND OPERATION
(PCM). Use of a induction milliampere ammeter, volt/
ohmmeter, battery charger, carbon pile rheostat (load STARTING SYSTEM
tester), and 12-volt test lamp may be required. The starting system components form two separate
All OBD-sensed systems are monitored by the circuits. A high-amperage feed circuit that feeds the
PCM. Each monitored circuit is assigned a Diagnos starter between 150 and 350 amperes (700 amperes -
tic Trouble Code (DTC). The PCM will store a DTC In diesel engine), and a low-amperage control circuit
electronic memory for any failure it detects. See the that operates on less than 20 amperes.
On-Board Diagnostics Test in Group 80 - Charging If the vehicle is equipped with an automatic transmis
System for more information. sion, battery voltage is supplied through the low-amper
age control circuit to the coil battery terminal of the
INTRODUCTION
starter relay when the ignition switch is turned to the
The starting system consists of:
Start position. If the vehicle is equipped with a manual
• Battery
transmission, it has a clutch pedal position switch. The
• Starter relay
clutch pedal position switch is connected in series
• Starter with an integral solenoid
between the ignition switch and the coil battery termi
• Ignition switch
nal of the starter relay. This normally open switch
8B - 2 STARTING SYSTEMS

closes only when the clutch pedal is depressed, prevent However, the starter motor and solenoid are serviced
ing starter operation while the clutch disc and the fly only as a complete assembly. I f either component fails,
wheel are engaged. the entire assembly must be replaced.
If the vehicle is equipped with an automatic trans
mission, the park/neutral position switch is installed STARTER RELAY
in series between the starter relay coil ground termi The starter relay is a International Standards
nal and ground. This normally open switch closes Organization (ISO)-type relay The starter relay is a
only with the automatic transmission gear selector in electro-mechanical device that switches current to
the Neutral or Park positions. In vehicles with a the pull-in coil of the starter solenoid, when the igni
manual transmission, the starter relay coil ground tion switch is turned to the Start position. See the
terminal Is always grounded. Diagnosis and Testing section of this group for more
With the starter relay coil now energized, the nor information on the starter relay's operation.
mally open relay contacts close. The relay contacts The starter relay Is located in the Power Distribu
connect the relay common feed terminal to the relay tion Center (PDC) in the engine compartment. Refer
normally open terminal. The closed relay contacts to the PDC label for relay identification and location.
energize the starter solenoid coil windings.
The energized solenoid pull-in coil pulls In the sole
noid plunger. The solenoid plunger pulls the shift DIAGNOSIS AND TESTING
lever In the starter. This engages the starter overrun
ning clutch and pinion gear with the starter ring STARTING SYSTEM
gear on the flywheel,(manual transmission) or torque For circuit descriptions and diagrams, refer to
converter (automatic transmission). 8W-21 - Starting System in Group 8W - Wiring Dia
As the solenoid plunger reaches the end of its grams.
travel, the solenoid contact disc completes the high-
INSPECTION •
amperage starter feed circuit and energizes the sole
Before removing any unit from the starting system
noid plunger hold-in coil. Current now flows between
for repair or diagnosis, perform the following inspec
the solenoid battery terminal and the starter motor,
tions:
energizing the starter.
• Battery - Visually inspect the battery for indi
Once the engine starts, the overrunning clutch pro
cations of physical damage and loose or corroded
tects the starter from damage by allowing the starter
cable connections. Determine the state-of-charge and
pinion gear to spin faster than the pinion shaft.
cranking capacity of the battery. Charge or replace
When the driver releases the ignition switch to the
the battery, i f required. Refer to Group 8A - Battery
On position, the starter relay coil is de-energized.
for more information.
This causes the relay contacts to open. When the
• Ignition Switch - Visually inspect the ignition
relay contacts open, the starter solenoid plunger
switch for indications of physical damage and loose
hold-in coil is de-energized.
or corroded wiring connections.
When the solenoid plunger hold-in coil Is de-ener
• Clutch Pedal Position Switch - Visually
gized, the solenoid plunger return, spring returns the
inspect the clutch pedal position switch for indica
plunger to its relaxed position. This causes the con
tions of physical damage and loose or corroded wiring
tact disc to open the starter feed circuit, and the shift
connections.
lever to disengage the overrunning clutch and pinion
• Park/Neutral Position Switch - Visually
gear from the starter ring gear.
inspect the park/neutral position switch for indica
STARTER
connections.
The starter motor Incorporates several features to
• Starter Relay - Visually inspect the starter
create a reliable,. efficient, compact, and lightweight
relay for indications of physical damage and loose or
unit. A planetary gear system (intermediate trans
corroded wiring connections.
mission) Is used between the electric motor and the
• Starter - Visually inspect the starter for indica
pinion gear. This feature makes i t possible to reduce
the dimensions of the starter. At the same time, it
connections.
allows higher armature rotational speed and delivers
• Starter Solenoid - Visually inspect the starter
increased torque through the pinion gear to the
solenoid for indications of physical damage and loose
starter ring gear on the flywheel (manual transmis
or corroded wiring connections.
sion), or torque converter (automatic transmission).
• Wiring - Visually inspect the wiring for damage.
The starter motors for all engines are activated by a
Repair or replace the faulty wiring, as required.
solenoid mounted to the overrunning clutch housing.
BR — — — — — ~ - STARTING SYSTEMS 8B - 3
Starting System Diagnosis
Starting System Diagnosis

STARTER FAILS TO ENGAGE. 1. Battery discharged or faulty. 1. Refer to Group 8A - Battery. Charge
2. Starting circuit wiring faulty. or replace battery, if required.
3. Starter relay faulty. 2. See Cold Cranking Test, in this
4. Ignition switch faulty. group. Test and repair feed and/or
5. Park/Neutral position switch (auto control circuits, if required.
trans) faulty or misadjusted. 3. See Relay Test, in this group.
6. Clutch pedal position switch (man Replace relay, if required.
trans) faulty. 4. See Ignition Switch Test, in this
7. Starter solenoid faulty. group. Replace switch, if required.
8. Starter assembly faulty. 5. See Park/Neutral Position Switch
Test, in this group. Replace switch, if
required.
6. See Clutch Pedal Position Switch
Test, in this group. Replace switch, if
required.
7. See Solenoid Test, in this Group.
Replace starter assembly, if required.
8. If all other starting system
components and circuits check OK,
replace starter assembly.
STARTER ENGAGES, FAILS TO 1. Battery discharged or faulty. 1. Refer to Group 8A - Battery. Charge
TURN ENGINE. 2. Starting circuit wiring faulty. or replace battery, if required.
3. Starter assembly faulty. 2. See Cold Cranking Test, in this
4. Engine seized. group. Test and repair feed and/or
control circuits, if required.
4. Refer to Group 9 - Engine, for
diagnostic and service procedures.
STARTER ENGAGES, SPINS 1. Broken teeth on starter ring gear. 1. Remove starter as described in this
OUT BEFORE ENGINE STARTS. 2. Starter assembly faulty. group. Inspect ring gear and replace, if
required.
STARTER DOES NOT 1. Starter improperly installed. 1. Install starter as described in this
DISENGAGE. 2. Starter relay faulty. group. Tighten starter mounting
3. Ignition switch faulty. hardware to correct torque
4. Starter assembly faulty. specifications.
2. See Relay Test, in this group.
Replace relay, if required.
3. See Ignition Switch Test, in this
group. Replace switch, if required.
8B - 4 STARTING SYSTEMS BR
COLD CRANKING TEST FRONT OF ENGINE AIR TEMPERATURE SENSOR

• SENSOR ELECTRICAL
For circuit descriptions and diagrams, refer to
CONNECTOR
8W-21 - Starting System in Group 8W - Wiring Dia
grams. The battery must be fully-charged and load-
tested before proceeding. Refer to Group 8A - Battery
(1) Connect a suitable volt-ampere tester to the
battery terminals (Fig. 1). Refer to the operating
instructions provided with the tester being used.
POSITIVE NEGATIVE
CLAMP CLAMP
INTAKE
MANIFOLD
FUEL
(UPPER HALF) SOLENOID
SHUTDOWN
SOLENOID ELECTRICAL
INDUCTION CONNECTOR
J9414-93
AMMETER
CLAMP
Fig. 2 Fuel Shutdown Solenoid Connector - Diesel
948A-24
Engine
Fig. 1 Volts-Amps Tester Connections - Typical (b) I f the voltage reads 12.5 volts or greater and
(2) Fully engage the parking brake. the current (amperage) draw reads below specifica
(3) Place the manual transmission gearshift selec tions, see the Control Circuit Tests in this group.
tor lever in the Neutral position and fully depress
NOTE: A cold engine will increase the starter cur
the clutch pedal. Place the automatic transmission
rent (amperage) draw reading, and reduce the bat
gear selector lever in the Park position.
tery voltage reading.
(4) Verify that all lamps and accessories are
turned off.
FEED CIRCUIT TESTS
WARNING: MODELS EQUIPPED WITH THE DIESEL
The starter feed circuit tests (voltage drop method)
ENGINE OPTION ALSO HAVE AN AUTOMATIC
will determine i f there is excessive resistance in the
SHUT-DOWN (ASD) RELAY LOCATED IN THE
high-amperage circuit. For circuit descriptions and
POWER DISTRIBUTION CENTER (PDC). HOWEVER,
diagrams, refer to 8W-21 - Starting System in Group
REMOVAL OF THE ASD RELAY MAY NOT PREVENT
8W -Wiring Diagrams.
THE DIESEL ENGINE FROM STARTING. BE CER
When performing these tests, it is important to
TAIN TO DISCONNECT THE FUEL SHUTDOWN
remember that the voltage drop is giving an indica
SOLENOID CONNECTOR. FAILURE TO DO SO MAY
tion of the resistance between the two points at
RESULT IN PERSONAL INJURY.
which the voltmeter probes are attached.
(5) To prevent a gasoline engine from starting, Example:When testing the resistance of the bat
unplug the Automatic Shut-Down (ASD) relay. To tery positive cable, touch the voltmeter leads to the
prevent a diesel engine from starting, disconnect the battery positive cable clamp and the cable connector
fuel shutdown solenoid connector (Fig. 2). The ASD at the starter solenoid. I f you probe the battery pos
relay is located in the Power Distribution Center itive terminal post and the cable connector at the
(PDC). Refer to the PDC label for relay identification starter solenoid, you are reading the combined volt
and location. age drop in the battery positive cable clamp-to-termi
(6) Rotate and hold the ignition switch in the Start nal post connection and the battery positive cable.
position. Note the cranking voltage and current The following operation will require a voltmeter
(amperage) draw. accurate to 1/10 (0.10) volt. Before performing the
(a) I f the voltage reads above 9.6 volts and the tests, be certain the following procedures are accom
current (amperage) draw reads above specifica plished:
tions, see the Feed Circuit Tests in this group.
BR STARTING SYSTEMS 81 - 1
DIAGNOSIS AND T E S T I N G fContlnueii

WARNING: MODELS EQUIPPED WITH THE DIESEL
ENGINE OPTION ALSO HAVE AN AUTOMATIC
SHUT-DOWN (ASD) RELAY LOCATED IN THE
POWER DISTRIBUTION CENTER (PDC). HOWEVER,
REMOVAL OF THE ASD RELAY MAY NOT PREVENT
THE DIESEL ENGINE FROM STARTING. BE CER
TAIN TO DISCONNECT THE FUEL SHUTDOWN
SOLENOID CONNECTOR. FAILURE TO DO SO MAY
RESULT IN PERSONAL INJURY.
© Battery is fully-charged. Refer to Group 8A -

Battery for more information.
• Fully engage the parking brake.
• Place the manual transmission gearshift selector
lever in the Neutral position and fully depress the
80660061
clutch pedal. Place the automatic transmission gear
selector lever in the Park position. Fig. 4 Test Battery Positive Connection Resistance -
• Unplug the Automatic Shut-Down (ASD) relay to Typical
prevent a gasoline engine from starting. The relay is
(3) Connect the voltmeter to measure between the
located in the Power Distribution Center (PDC).
battery positive terminal post and the starter sole
Refer to the PDC label for relay identification and
location. To prevent a diesel engine from starting, noid battery terminal stud (Fig. 5). Rotate and hold
disconnect the fuel shutdown solenoid connector (Fig. the ignition switch in the Start position. Observe the
2). voltmeter. I f the reading is above 0.2 volt, clean and
tighten the battery cable connection at the solenoid.
(1) Connect the positive lead of the voltmeter to
Repeat the test. I f the reading is still above 0.2 volt,
the battery negative terminal post. Connect the neg
replace the faulty battery positive cable.
ative lead of the voltmeter to the battery negative
cable clamp (Fig. 3). Rotate and hold the ignition
switch i n the Start position. Observe the voltmeter. I f
voltage is detected, correct the poor contact between
the cable clamp and the terminal post.
Fig. 5 Test Battery Positive Cable Resistance -

Typical
(4) Connect the voltmeter to measure between the
battery negative terminal post and a good clean
ground on the engine block (Fig. 6). Rotate and hold
the ignition switch in the Start position. Observe the
Fig. 3 Test Battery Negative Connection Resistance voltmeter. I f the reading is above 0.2 volt, clean and
- Typical tighten the battery negative cable attachment on the
(2) Connect the positive lead of the voltmeter to engine block. Repeat the test. I f the reading is still
the battery positive terminal post. Connect the nega above 0.2 volt, replace the faulty battery negative
tive lead of the voltmeter to the battery positive cable cable.
clamp (Fig. 4). Rotate and hold the ignition switch in (5) Connect the positive lead of the voltmeter to
the Start position. Observe the voltmeter. I f voltage the starter housing. Connect the negative lead of the
is detected, correct the poor contact between the voltmeter to the battery negative terminal post (Fig.
cable clamp and the terminal post. 7). Rotate and hold the ignition switch in the Start
8B - 6 STARTING SYSTEMS BR
SOLENOID TEST
Remove the starter as described in this group.
Then proceed as follows:
(1) Disconnect the wire from the solenoid field coil
terminal.
(2) Check for continuity between the solenoid ter
minal and the field coil terminal with a continuity
tester (Fig. 8). There should be continuity. I f OK, go
to Step 3. If not OK, replace the faulty starter assem-
bly.
Fig. 6 Test Ground Circuit Resistance -Typical

position. Observe the voltmeter. I f the reading Is
above 0.2 volt, correct the poor starter to engine
block ground contact.
Fig. 8 Continuity Test Between Solenoid Terminal
and Field Coil Terminal
(3) Check for continuity between the solenoid ter
minal and the solenoid case (Fig. 9). There should be
continuity. I f OK, go to Step 4. I f not OK, replace the
faulty starter assembly.
SOLENOID
RR8BD33
Fig. 7 Test Starter Ground - Typical Fig. 9 Continuity Test Between Solenoid Terminal
If the resistance tests detect no feed circuit prob and Solenoid Case
lems, remove the starter and see the Solenoid Test i n (4) Connect the solenoid field coil wire to the field
this group. coil terminal.
(5) Install the starter as described in this group.
CONTROL CIRCUIT TESTS
For circuit descriptions and diagrams, refer to R E L A Y TEST
8W-21 - Starting System in Group 8W - Wiring Dia The starter relay is located in the Power Distribu
grams. The starter control circuit consists of: tion Center (PDC) in the engine compartment. Refer
® Battery to the PDC label for relay identification and location.
• Starter relay Remove the starter relay from the PDC as
• Starter solenoid described in this group to perform the following tests:
• Ignition switch (1) A relay in the de-energized position should
• Park/neutral position switch (automatic trans have continuity between terminals 87A and 30, and
mission) no continuity between terminals 87 and 30. I f OK, go
• Clutch pedal position switch (manual transmis to Step 2. I f not OK, replace the faulty relay.
sion) (2) Resistance between terminals 85 and 86 (elec
• Wiring harness and connections. tromagnet) should be 75±5 ohms. I f OK, go to Step
Test procedures for these components should be 3. I f not OK, replace the faulty relay.
performed in the order in which they are listed, as (3) Connect a battery to terminals 85 and 86.
follows: There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A
BR JllKIiNG SYSTEMS 8B - 7

and 30. I f OK, see the Relay Circuit Test In this lever is in the Park or Neutral positions. On vehicles
group. I f not OK, replace the faulty relay. with a manual transmission, it is grounded at all times.
RELAY CAVITIES
Check for continuity to ground at the cavity for relay
RELAY TERMINALS
terminal 85. I f not OK with an automatic transmission,
87A check for an open or short circuit to the park/neutral
87 position switch and repair, i f required. I f the circuit is
OK, see the Park/Neutral Position Switch Test in this
85 | 87A j 86 group. I f not OK with a manual transmission, repair
the circuit to ground as required.
30
PARK/NEUTRAL POSITION SWITCH TEST
(1) Place the transmission gear selector lever in
J958A-2 the Park position.
TERMINAL LEGEND
NUMBER i IDENTIFICATION
(2) Disconnect and isolate the battery negative
30 C O M M O N FEED cable.
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN (4) Disconnect the park/neutral position switch
87A NORMALLY CLOSED
harness connector.
(5) Check for continuity between the center switch
Starter Relay terminal and a good chassis ground. There should be
RELAY CIRCUIT TEST continuity. I f OK, go to Step 6. I f not OK, replace the
(1) The relay common feed terminal cavity (30) is faulty switch.
connected to battery voltage and should be hot at all (6) Move the transmission gear selector lever to
times. I f OK, go to Step 2. I f not OK, repair the open the Reverse position and check ' for continuity
circuit to the PDC fuse as required,, between the center switch terminal and a good chas
(2) The relay normally closed terminal (87A) is sis ground. There should be no continuity. I f not OK,
connected to terminal 30 In the de-energized position, replace the faulty switch.
but is not used for this application. Go to Step 3.
(3) The relay normally open terminal (87) Is con CLUTCH PEDAL POSITION SWITCH TEST
nected to the common feed terminal (30) In the ener The clutch pedal position switch is integral to the
gized position. This terminal supplies battery voltage clutch pedal pushrod. I t is located near the dash
to the starter solenoid field coils. There should be panel under the instrument panel. The harness con
continuity between the cavity for relay terminal 87 nector for the switch is wrapped with foam tape.
and the starter solenoid terminal at all times. I f OK, (1) Disconnect and isolate the battery negative
go to Step 4. I f not OK, repair the open circuit to the cable.
starter solenoid as required. (2) Disconnect the switch harness connector.
(4) The coil battery terminal (86) is connected to (3) Check for continuity between the two cavities in
the electromagnet in the relay. I t is energized when the switch-half of the harness connector with the clutch
the Ignition switch is held In the Start position. On pedal released. There should be no continuity. I f OK, go
vehicles with a manual transmission, the clutch to Step 4. I f not OK, replace the faulty switch.
pedal must be fully depressed for this test. Check for (4) Check for continuity between the two cavities
battery voltage at the cavity for relay terminal 86 in the switch-half of the harness connector again
with the ignition switch in the Start position, and no with the clutch pedal depressed. There should now be
voltage when the ignition switch is released to the continuity. I f OK, see the Ignition Switch Test in this
On position. I f OK, go to Step 5. I f not OK with an group. I f not OK, replace the faulty switch.
automatic transmission, check for an open or short
circuit to the ignition switch and repair, i f required. IGNITION SWITCH TEST
I f the circuit to the Ignition switch is OK, see the
Ignition Switch Test in this group. I f not OK with a WARNING: ON VEHICLES EQUIPPED WITH AN AIR-
manual transmission, check the circuit between the BAG, REFER TO GROUP 8M - PASSIVE RESTRAINT
relay and the clutch pedal position switch for an SYSTEMS BEFORE ATTEMPTING STEERING
open or a short. I f the circuit is OK, see the Clutch WHEEL OR STEERING COLUMN COMPONENT
Pedal Position Switch Test in this group. DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI
(5) The coil ground terminal (85) is connected to the
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
electromagnet in the relay. On vehicles with an auto
PERSONAL INJURY.
matic transmission, it is grounded through the park/
neutral position switch only when the gearshift selector
8B - 8 STARTING SYSTEMS
DIAGNOSIS AND TESTING fContinued)

cable.
(2) Remove the steering column shrouds and dis
connect the ignition switch harness connector. Refer
to Group 8D - Ignition Systems for the procedures.
(3) With the ignition switch i n the On position,
check for continuity between the ignition switch ter
minals 1 and 7. These are the terminals at each end
of the switch connector. There should be no continu
ity. I f OK, go to Step 4. I f not OK, replace the faulty
switch.
(4) With the ignition switch held i n the Start posi
tion, check for continuity between the ignition switch
terminals 1 and 7 again. There should now be conti
nuity. I f not OK, replace the faulty switch.
STARTER
GASOLINE ENGINE
cable.
(3) Remove the nuts from the terminal studs for
the starter battery lead and solenoid lead (Fig. 10) or
(Fig. 11).
WIRE NUT AND WASHER
80315842
Fig. 10 Starter Connector Remove/Install - V-6/V-8
Engine
Fig. 12 Starter Mounting Hardware Remove/instaii -
(4) Remove the hardware securing the starter to V-6A/-8 Engine
the bellhousing (Fig. 11) or (Fig. 12).
(5) Move the starter forward to clear the lower o Solenoid lead terminal nut - 2.5 N-m (22 in.
mounting stud (V-6/V-8 engine) and for the starter lbs.).
gear housing nose to clear the bellhousing. This
DIESEL ENGINE
allows the starter to come down past the exhaust
(1) Disconnect and isolate both of the battery neg
pipe (Fig. 11) or (Fig. 13).
ative cables.
(6) Reverse the removal procedures to install.
Tighten the starter hardware as follows:
(3) Remove the battery lead from the solenoid ter
• Starter mounting bolts to 68 N-m (50 ft. lbs.)
minal by pulling the rubber boot up and removing
• Starter mounting nut - 27 N-m (20 ft. lbs.)
the nut (Fig. 14).
• Battery lead terminal nut - 14 N-m (120 in. lbs.)
(4) Remove the nut from the solenoid lead termi
nal at the solenoid.
BR — — „ _ _ STARTING SYSTEMS 8B - 9
HEHiOWAL mm mmikLLmmm {Continued)

(5) Remove the starter mounting bolts (Fig. 14)
and (Fig. 15).
Fig. 15 Starter Mounting Bolt - Diesei Engine

(6) Remove the starter motor. *
Tighten the starter hardware as follows:
• Starter mounting bolts - 43 N-m (32 ft. lbs.)
• Solenoid lead nut - 6 N-m (55 in. lbs.)
• Battery lead nut - 10 N-m (90 in. lbs.).
Fig. 14 Starter Connectors Remove/lnstaii - Diesel

Engine
8B - 1 0 STARTING SYSTEMS BR
STARTER RELAY
(1) Disconnect and Isolate the battery negative
cable(s).
(2) Remove the cover from the Power Distribution
Center (PDC) (Fig. 16).
(3) Refer to the label on the PDC for starter relay
identification and location.
(4) Remove the starter relay by unplugging i t from
the PDC.
(5) Install the starter relay by aligning the relay
terminals with the cavities in the PDC and pushing
the relay firmly into place.
(6) Install the PDC cover.
(7) Connect the battery negative cable(s).
(8) Test the relay operation.
Fig. 16 Power Distribution Center
SPECIFICATIONS
STARTING SYSTEM
Starter and Solenoid

Engine Application 3.9L, 5.2L, 5.9L (Gas) 8.0L 5.9L (Diesel)
Manufacturer Nippon Denso Nippon Denso Nippon Denso
Part Number 56027702 56004757 47410"!.?
Power Rating i .4 Kilowatt 1.4 Kilowatt 2.7 Kilowatt

Voltage 12 Volts 12 Volts 12 Volts
Number of Fields 4 4 4
Number of Poles 4 4 4
Number of Brushes 4 4 4
Drive Type Reduction Gear Train Reduction Gear Train Conventional Gear Train
Free Running Test
11 Volts 11 Volts 11 Volts
Voltage
Free Running Test
73 Amperes 73 Amperes 200 Amperes
Amperage Draw
Free Running Test
3601 rpm 3601 rpm 3000 rpm
Minimum Speed
Solenoid Closing Voltage 7.5 Volts 7.5 Volts 8.0 Volts
Cranking Amperage
125 - 250 Amperes 125 - 250 Amperes 450 - 700 Amperes
Draw Test*
"Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw
BR CHARGING SYSTEM au - i
CHARGING SYSTEM
CONTENTS
page page
GENERAL INFORMATION CHARGING SYSTEM 2

OVERVIEW 1 CURRENT OUTPUT TEST . . . . . . . . . . . . . . . . . . 3
DESCRIPTION AND OPERATION ON-BOARD DIAGNOSTIC SYSTEM TEST . . . . . . 6
BATTERY TEMPERATURE SENSOR 2 REMOVAL AND INSTALLATION
CHARGING SYSTEM OPERATION 1 BATTERY TEMPERATURE SENSOR . . . . . . . . . . 8
GENERATOR 2 GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
VOLTAGE REGULATOR 2 SPECIFICATIONS
DIAGNOSIS AND TESTING GENERATOR RATINGS . . . . . . . . . . . . . . . . . . . . 9
BATTERY TEMPERATURE SENSOR 6 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . 9
CHARGING SYSTEM RESISTANCE T E S T S 3
G E N E R A L INFORMATION DESCRIPTION AND OPERATION

OVERVIEW CHARGING SYSTEM OPERATION
The. battery, starting, and charging systems oper The charging system consists of:
ate with one another, and must be tested as a com • Generator
plete system. In order for the vehicle to start and • Electronic Voltage Regulator (EVR) circuitry
charge properly, all of the components Involved In within the Powertrain Control Module (PCM)
these systems must perform within specifications. • Ignition switch (refer to Group 8D, Ignition Sys
Group 8A covers the battery, Group 8B covers the tem for information)
starting system, and Group 8C covers the charging • Battery (refer to Group 8A, Battery for informa
system. Refer to Group 8W - Wiring Diagrams for tion)
complete circuit descriptions and diagrams. We have • Battery temperature sensor
separated these systems to make it easier to locate • Voltmeter (refer to Group 8E, Instrument Panel
the information you are seeking within this Service and Gauges for information)
Manual. However, when attempting to diagnose any • Wiring harness and connections (refer to Group
of these systems, i t Is important that you keep their 8W, Wiring for Information)
interdependency in mind. The charging system is turned on and off with the
The diagnostic procedures used In these groups ignition switch. When the ignition switch is turned to
include the most basic conventional diagnostic meth the ON position, battery voltage Is applied to the
ods to the more sophisticated On-Board Diagnostics generator rotor through one of the two field termi
(OBD) built into the Powertrain Control Module nals to produce a magnetic field. The generator is
(PCM). Use of a induction milliampere ammeter, volt/ driven by the engine through a serpentine belt and
ohmmeter, battery charger, carbon pile rheostat (load pulley arrangement.
tester), and 12-volt test lamp may be required. The amount of DC current produced by the gener
All OBD-sensed systems are monitored by the ator is controlled by the EVR (field control) circuitry,
PCM. Each monitored circuit is assigned a Diagnos contained within the PCM. This circuitry is con
tic Trouble Code (DTC). The PCM will store a DTC in nected in series with the second rotor field terminal
electronic memory for any failure i t detects. See the and ground.
On-Board Diagnostics Test i n Group 8C - Charging A battery temperature sensor located In the bat
System for more information. tery tray housing, is used to sense battery tempera
ture. This temperature data, along with data from
monitored line voltage, is used by the PCM to vary
the battery charging rate. This is done by cycling the
ground path to control the strength of the rotor mag
netic field. The PCM then compensates and regulates
generator current output accordingly.
oh - 1 CHARGING SYSTEM BR

All vehicles are equipped with On-Board Diagnos
tics (OBD). A l l OBD-sensed systems, including the BATTERY
EVR (field control) circuitry, are monitored by the
PCM. Each monitored circuit is assigned a Diagnos
tic Trouble Code (DTC). The PCM will store a DTC in
electronic memory for any failure i t detects. See On-
Board Diagnostic System Test in this group for more
information.
GENERATOR . ,
The generator is belt-driven by the engine using a
serpentine type drive belt. I t is serviced only as a
complete assembly. I f the generator fails for any rea
son, the entire assembly must be replaced.
As the energized rotor begins to rotate within the
generator, the spinning magnetic field Induces a cur
rent into the windings of the stator coil. Once the
generator begins producing sufficient current, i t also
provides the current needed to energize the rotor.
The Y type stator winding connections deliver the
induced AC current to 3 positive and 3 negative
diodes for rectification. From the diodes, rectified DC
current is delivered to the vehicle electrical system
through the generator battery and ground terminals.
Although the generators appear the same exter
nally, different generators with different output rat
ings are used on this vehicle. This will depend upon
engine size and optional equipment. Be certain that
the replacement generator has the same output rat Fig. 1 Battery Temperature Sensor Location
ing as the original unit. See Generator Ratings in the I f replacement is necessary, the PCM must be
Specifications section at the back' of this group for replaced.
amperage ratings. Operation: The amount of DC current produced
Noise emitting from the generator may be caused by the generator is controlled by EVR circuitry con
by: worn, loose or defective bearings; a loose or defec tained within the PCM. This circuitry is connected i n
tive drive pulley; incorrect, worn, damaged or misad- series with the generators second rotor field terminal
justed fan drive belt; loose mounting bolts; a and its ground.
misaligned drive pulley or a defective stator or diode. Voltage is regulated by cycling the ground path to
control the strength of the rotor magnetic field. The
BATTERY TEMPERATURE SENSOR
EVR circuitry monitors system line voltage and bat
The battery temperature sensor is used to deter tery temperature (refer to Battery Temperature Sen
mine the battery temperature and control battery sor for more information). I t then compensates and
charging rate. This temperature data, along with regulates generator current output accordingly. Also
data from monitored line voltage, Is used by the PCM see Charging System Operation for additional infor
to vary the battery charging rate. System voltage will mation.
be higher at colder temperatures and is gradually
reduced at warmer temperatures.
The sensor is located under the vehicle battery and DIAGNOSIS AND TESTING
is attached (snapped into) the battery tray (Fig. 1).
On models equipped with a diesel engine (dual bat CHARGING SYSTEM
teries), only one sensor is used. Location is under When the ignition switch is turned to the ON posi
battery on drivers side of vehicle. tion, battery potential will register on the voltmeter.
During engine cranking a lower voltage will appear
VOLTAGE REGULATOR on the meter. With the engine running, a voltage
The voltage regulator is not a separate component. reading higher than the first reading (ignition i n ON)
It is actually a voltage regulating circuit located should register.
within the PCM. This EVR is not serviced separately.
BR CHARGING SYSTE1 SC - 3
The following procedures may be used to diagnose (3) Start the engine and allow it to reach normal
the charging system if: operating temperature.
• the voltmeter does not operate properly (4) Shut engine off.
• an undercharged or overcharged battery condi (5) Connect an engine tachometer.
tion occurs. (6) Fully engage the parking brake.
Remember that an undercharged battery is often
caused by: TEST
• accessories being left on with the engine not (1) Start engine.
running (2) Place heater blower in high position.
• a faulty or improperly adjusted switch- that (3) Turn on headlamps and place i n high-beam
allows a lamp to stay on. See Ignition-Off Draw Test position.
in Group 8A, Battery for more information. (4) Turn vehicle interior lamps on.
(5) Start engine. Bring engine speed up to 2400
INSPECTION rpm and hold.
(1) Inspect condition of battery cable terminals, (6) Testing (+) circuitry:
battery posts, connections at engine block, starter (a) Touch the negative lead of voltmeter directly
solenoid and relay. They should be clean and tight. to battery positive post.
Repair as required. (b) Touch the positive lead of voltmeter to the
(2) Inspect all fuses in the fuseblock module and B + output terminal stud on the generator (not the
Power Distribution Center (PDC) for tightness in terminal mounting nut). Voltage should be no
receptacles. They should be properly installed and higher than 0.6 volts. I f voltage is higher than 0.6
tight. Repair or replace as required. volts, touch test lead to terminal mounting stud
(3) Inspect the electrolyte level i n the battery. nut and then to the wiring connector. I f voltage is
Replace battery i f electrolyte level is low. now below 0.6 volts, look for dirty, loose or poor
(4) Inspect generator mounting bolts for tightness. connection at this point. Also check condition of the
Replace or tighten bolts i f required. Refer to the Gen generator output wire-to-battery bullet connector.
erator Removal/Installation section of this group for Refer to Group 8, Wiring for connector location. A
torque specifications. voltage drop test may be performed at each (+) con
(5) Inspect generator drive belt condition and ten nection i n this circuit to locate the excessive resis
sion. Tighten or replace belt as required. Refer to tance.
Belt Tension Specifications in Group 7, Cooling Sys (7) Testing (-) circuitry:
tem. (a) Touch the negative lead of voltmeter directly
(6) Inspect automatic belt tensioner (if equipped). to battery negative post.
Refer to Group 7, Cooling System for information. (b) Touch the positive lead of voltmeter to the
(7) Inspect connections at generator field, battery ground terminal stud on the generator case (not
output, and ground terminals. Also check ground con the terminal mounting nut). Voltage should be no
nection at engine. They should all be clean and tight. higher than 0.3 volts. I f voltage is higher than 0.3
Repair as required. volts, touch test lead to terminal mounting stud
nut and then to the wiring connector. I f voltage is
CHARGING S Y S T E i RESISTANCE TESTS now below 0.3 volts, look for dirty, loose or poor
These tests will show the amount of voltage drop connection at this point. A voltage drop test may be
across the generator output wire, from the generator performed at each (-) connection i n this circuit to
output (B+) terminal (Fig. 2) to the battery positive locate the excessive resistance. This test can also
post. They will also show the amount of voltage drop be performed between the generator case and the
from the ground (-) terminal on the generator (Fig. 2) engine. I f test voltage is higher than 0.3 volts,
to the battery negative post. check for corrosion at generator mounting points or
A voltmeter with a 0-18 volt DC scale should be loose generator mounting.
used for these tests. By repositioning the voltmeter
test leads, the point of high resistance (voltage drop) CURRENT OUTPUT TEST
can easily be found. The current output test will determine i f the
charging system can deliver its minimum test cur
PREPARATION rent (amperage) output. Refer to the Specifications
(1) Before starting test, make sure battery is in section at the end of this group for minimum test
good condition and is fully-charged. See Group 8A, current (amperage) requirements.
Battery for more information. The first part of this test (Test 1) will determine
(2) Check condition of battery cables at battery. the combined amperage output of both the generator
Clean i f necessary. and the Electronic Voltage Regulator (EVR) circuitry.
8C - 4 CHARGING SYSTEM — — - — -
CHECK BATTERY CONDITION.

CHARGE BATTERY IF NECESSARY.
CHECK DRIVE BELT. REFER GROUP 7, COOLING

SYSTEM FOR ACCESSORY DRIVE BELTS.
CHECK GENERATOR GROUND PATH
YES
CLEAN MOUNTING SURFACES
TIGHTEN FASTENERS TO
SPECIFIED TORQUE.
CHECK ON BOARD DIAGNOSTIC

TROUBLE CODES (DTC).
f
PERFORM OUTPUT VOLTAGE TEST
REFER TO LOW OR NO
VOLTAGE TEST.
YES
REFER TO CHARGING SYSTEM AND
OVERCHARGE TEST. GENERATOR IS OK.
Charging System Test

BR — — •—•— —•— CHARGING SYSTEM 8C - S
D I A G N O S I S A N D T E S T I N G (Continued^
(8) Shut engine off.

(9) Turn off all electrical accessories and all vehicle
GROUND lighting.
(10) Connect the volt/amp tester leads to the bat
tery. Be sure the carbon pile rheostat control is i n the
OPEN or OFF position before connecting leads. See
Load Test in Group 8A, Battery for more information.
Also refer to the operating instructions supplied with
test equipment.
(11) Connect the inductive clamp (ammeter probe).
Refer to the operating instructions supplied with test
equipment.
(12) I f volt/amp tester is not equipped with an
engine tachometer, connect a separate tachometer to
the engine.
TEST 1
(1) Perform the previous test Preparation.
(+) ASD RELAY (2) Fully engage the parking brake.
OUTPUT TERMINAL (3) Start engine.
(4) Bring engine speed to 2500 rpm.
8020cd8c
(5) With engine speed held at 2500 rpm, slowly
Fig. 2 Generator Terminals adjust the rheostat control (load) on the tester to
obtain the highest amperage reading. Do not allow
The second part of this test (Test 2) will determine voltage to drop below 12 volts. Record the reading.
only generator amperage and will not include anal This load test must be performed within 15 sec
ysis of EVR circuitry. EVR circuitry is located within onds to prevent damage to test equipment. On
the Powertrain Control Module (PCM). To test volt certain brands of test equipment, this load will be
age regulator circuitry refer to the appropriate Pow applied automatically. Refer to the operating manual
ertrain Diagnostic Procedures service manual. supplied with test equipment.
(6) The ammeter reading must meet the Minimum
PREPARATION
Test Amps specifications as displayed i n the Genera
(1) Determine i f any Diagnostic Trouble Codes
tor Ratings chart. This can be found in the Specifica
(DTCs) exist. To determine a DTC, refer to On-Board
tions section at the end of this group. A label stating
Diagnostics in this group. For repair, refer to the
a part reference number is attached to the generator
appropriate Powertrain Diagnostic Procedures man
case. On some engines this label may be located on
ual.
the bottom of the case. Compare this reference num
(2) Before starting test, make sure battery is i n
ber to the Generator Ratings chart.
good condition and is fully-charged. See Group 8A,
(7) Rotate the load control to the OFF position.
Battery for more information.
(8) Continue holding engine speed at 2500. I f EVR
(3) Check condition of battery cables at battery.
circuitry is OK, amperage should drop below 15-20
Clean i f necessary.
amps. With all electrical accessories and vehicle
(4) Perform the previous Output Wire Resistance
lighting off, this could take several minutes of engine
Test (voltage drop test). This will ensure clean and
operation. I f amperage did not drop, refer to the
tight generator/battery electrical connections.
(5) Be sure the generator drive belt is properly
ual for testing.
tensioned. Refer to Group 7, Cooling System for
(9) Remove volt/amp tester.
information.
I f minimum amperage could not be met, proceed to
(6) A volt/amp tester equipped with both a battery
Test 2. This test will determine i f the generator is
load control (carbon pile rheostat) and an inductive-
faulty, or i f EVR circuitry is defective.
type pickup clamp (ammeter probe) will be used for
this test. Refer to operating instructions supplied TEST 2
with tester. When using a tester equipped with an (1) Perform the previous test preparation.
inductive-type clamp, removal of wiring at the gener (2) Fully engage the parking brake.
ator will not be necessary. (3) Connect one end of a jumper wire to a good
(7) Start the engine and allow i t to reach operating ground. Connect the other end of jumper wire to the
temperature. (-) field control circuit terminal. This terminal is
8C - § CHARGING SYSTEM BR
D I A G N O S I S A N D TESTING (Continued)
located on the back of the generator (Fig. 2). Con (1) The sensor is located under the battery and is
necting the jumper wire will remove the voltage reg attached (snapped into) the battery tray (Fig. 1). A
ulator circuitry from the test. I t will also generate a' two-wire pigtail harness is attached directly to the
Diagnostic Trouble Code (DTC). sensor. The opposite end of this harness connects the
sensor to the engine wiring harness.
CAUTION; Do not connect the jumper wire t o the (2) Disconnect the two-wire pigtail harness from
(+) ASD Relay output terminal (Fig. 2). Damage to the engine harness.
electrical system components may result. The (-) (3) Attach ohmmeter leads to the wire terminals of
field control circuit terminal is located farther away the pigtail harness.
from the B+ output terminal than the (+) ASD Relay (4) At room temperature of 25° C (75-80° F), an
terminal (Fig. 2 ) . ohmmeter reading of 9 to 11K ohms should be
observed.
(4) Start engine. Immediately after starting, (5) I f reading is above or below the specification,
reduce engine speed to idle. This will prevent any replace the sensor.
electrical accessory damage from high voltage. (6) Refer to the Removal and Installation section
(5) Adjust carbon pile rheostat (load) and engine for procedures.
speed in slow increments until a speed of 1250 rpm,
and a voltmeter reading of 15 volts is obtained. ON-BOARD DIAGNOSTIC SYSTEM TEST
Immediately record ammeter reading. Do not apply
load to system longer than 15 seconds as damage to GENERAL INFORMATION
test equipment may result. The Powertrain Control Module (PCM) monitors
critical input and output circuits of the charging sys
CAUTION: When adjusting rheostat load, do not tem, making sure they are operational. A Diagnostic
allow voltage to rise above 16 volts. Damage to the Trouble Code (DTC) is assigned to each input and
battery and electrical system components may output circuit monitored by the OBD system. Some
result. circuits are checked continuously and some are
checked only under certain conditions.
(6) The ammeter reading must meet the Minimum
If the OBD system senses that a monitored circuit
Test Amps specifications as displayed in the Genera
is bad, i t will put a DTC into electronic memory. The
tor Ratings chart. This can be found in the Specifica
DTC will stay in electronic memory as long as the
tions section at the end of this group. A label stating
circuit continues to be bad. The PCM is programmed
a part reference number is attached to the generator
to clear the memory after 50 engine starts i f the
case. On some engines this label may be located on
problem does not occur again.
the bottom of the case. Compare this reference num
ber to the Generator Rating chart. DIAGNOSTIC TROUBLE CODES
(7) Remove volt/amp tester. Diagnostic Trouble Codes (DTC) are two-digit num
(8) Remove jumper wire. bers flashed on the malfunction indicator (Check
(9) Use the DRB scan tool to erase the DTC. Refer Engine) lamp that identify which circuit is bad. Refer
to the DRB screen for procedures. to Group 14, Fuel Systems for more information. A
DTC description can also be read using the DRB scan
RESULTS
tool. Refer to the appropriate Powertrain Diagnostic
• I f amp reading meets specifications in Test 2,
Procedures manual for information.
generator is OK.
A DTC does not identify which component in a cir
• I f amp reading is less than specified in Test 2 ,
cuit is bad. Thus, a DTC should be treated as a
and wire resistance (voltage drop) tests were OK, the
symptom, not as the cause for the problem. I n some
generator should be replaced. Refer to Removal and
cases, because of the design of the diagnostic test
Installation in this group for procedures.
procedure, a DTC can be the reason for another DTC
• I f Test 2 results were OK, but Test 1 results
to be set. Therefore, i t is important that the test pro
were not, the problem is in EVR circuitry. Refer to
cedures be followed in sequence, to understand what
caused a DTC to be set.
ual for diagnosis.
See the Generator Diagnostic Trouble Code chart
(Fig. 3) for DTCs which apply to the charging sys
BATTERY TEMPERATURE SENSOR
tem. Refer to the Powertrain Diagnostic Procedures
To perform a complete test of this sensor and its
manual to diagnose an on-board diagnostic system
circuitry, refer to the appropriate Powertrain Diag
trouble code.
nostic Procedures manual. To test the sensor only,
refer to the following:
BR — — — — — CHARGING SYSTEM 8C - 7
DIAGNOSIS AMD T E S T I N G (Continued)
Diagnostic DRB Scan Too!

Trouble Display Description of Diagnostic Trouble Code
Code
12*.... Battery Disconnect Direct battery input to PCM was disconnected within the last 50 key-on cycles.
41 **. Generator Field Not An open or shorted condition detected in the generatorfieldcontrol circuit.
Switching Properly
46**.... Charging System Battery voltage sense input above target charging voltage during engine operation.
Voltage Too High
47** Charging System Battery voltage sense input below target charging during engine operation.
Voltage Too Low Also, no significant change detected in battery voltage during active test of
generator output.
55* N/A Completion of fault code display on Check Engine lamp.

* Check Engine lamp will not illuminate at all times if this Diagnostic Trouble Code was recorded. Cycle ignition key as
described in manual and observe code flashed by Check Engine lamp.
* * Check Engine lamp will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
J958A-7
Fig. 3 Generator Diagnostic Trouble Code

RETRIEVING DIAGNOSTIC TROUBLE CODES (1) Disconnect negative battery cable.
To start this function, cycle the ignition switch ON- (2) Remove generator drive belt. Refer to Group 7,
OFF-ON-OFF-ON within 5 seconds. This will cause Cooling System for procedure.
any DTC stored i n the PCM memory to be displayed. (3) Remove the generator pivot and mounting bolts
The malfunction indicator (Check Engine) lamp will (Fig. 4). Position generator for access to wire connec
display a DTC by flashing on and off. There is a tors.
short pause between flashes and a longer pause
between digits. AH DTCs displayed are two-digit GENERATOR
MOUNTING
numbers, with a four-second pause between codes. BOLTS
An example of a DTC is as follows:
(1) Lamp on for 2 seconds, then turns off.
(2) Lamp flashes 4 times pauses and then flashes
1 time.
(3) Lamp pauses for 4 seconds, flashes 4 times,
pauses, then flashes 7 times.
(4) The two DTCs are 41 and 47. Any number of
DTCs can be displayed, as long as they are i n mem
ory. The lamp will flash until all stored DTCs are
displayed, then i t will flash a DTC 55 to indicate the
test is complete.
ERASING DIAGNOSTIC TROUBLE CODES

The DRB Scan Tool must be used to erase a DTC.
Fig. 4 Remove/Install Generator—Typical
REH©WAL A N P INSTALLATION (4) Remove nuts from harness holddown, battery

terminal, ground terminal and 2 field terminals (Fig.
GENERATOR 5). Remove wire connectors.
(5) Remove the generator.
WARNING: DISCONNECT NEGATIVE CABLE FROM (6) Reverse removal procedures to install. Tighten
BATTERY BEFORE REMOVING BATTERY OUTPUT generator hardware as follows:
WIRE FROM GENERATOR. FAILURE TO DO SO • Generator mounting bolt - 41 N-m (30 ft. lbs.)
CAN RESULT IN INJURY. • Generator pivot bolt - 41 N-m (30 ft. lbs.)
• Battery terminal nut - 8.5 N-m (75 in. lbs.)
8C - 8 CHARGJHG SYSTEM BR
REMQW&h Mm INSTALLATION ( C o n t i n u e d )
one sensor is used. The sensor is located under the
battery on drivers side of vehicle.
BATTERY
Fig. 5 Remove/instail Generator Connectors—

Typical
• Ground terminal nut - 8.5 N-m (75 in. lbs.)
© Harness holddown nut - 8.5 N-m (75 in. lbs.)
© Field terminal nuts - 2.8 N-m (25 in. lbs.)
CAUTION: Newer force a belt over a pulley rim

8056d9f6
using a screwdriver, Ths synthetic fiber of the belt
can be damaged, Fig. 6 Battery Temperature Sensor Location
REMOVAL
CAUTION: When installing a serpentine accessory (1) Remove the battery. Refer to Group 8A, Battery
drive belt, the belt MUST be routed correctly. The for procedures.
water pump will be rotating in the w r o n g direction if (2) Disconnect the sensor pigtail harness from the
the belt is installed incorrectly, causing the engine engine wire harness.
to overheat. Refer to belt routing label in engine (3) Pry the sensor straight up from the battery
compartment, or refer t o Belt Schematics in Group tray mounting hole.
7, Cooling System.
INSTALLATION
(1) Feed the pigtail harness through the mounting
BATTERY TEMPERATURE SENSOR hole in top of battery tray and press sensor into top
The battery temperature sensor is located under of tray (snaps in).
the vehicle battery (Fig. 6) and is attached (snapped (2) Connect the pigtail harness.
into) a mounting hole on battery tray. On models (3) Install the battery. Refer to Group 8A, Battery
equipped with a diesel engine (dual batteries), only for procedures.
LIR CHARGING SYSTEM 8C - 9
SPECIFICATIONS
GENERATOR RATINGS
TYPE PART NUMBER RATED SAE AMPS ENGINES MINIMUM TEST AMPS
DENSO 53008646 81 3.9L/5.2L/5.9L 75
DENSO 53008647 117 3.9L/5.2L/5.9L 90
DENSO 53008651 136 3.9L/5.2L/5.9L 120
DENSO 56027221 136 DIESEL 120
TORQUE SPECiFiCATiOIS
DESCEIPTION TOEQUE
Generator Mounting Bolt—
All Engines .41 N-m (30 ft. lbs.)
Generator Pivot Bolt—
All Engines 41 N-m (30 ft. lbs.)
Battery Terminal N u t . . . . . . . . .8.5 N-m (75 in. lbs.)
Ground Terminal N u t . . . . . . . . .8.5 N-m (75 in. lbs.)
Harness Hold-down Nut . . . . . . .8.5 N-m (75 in. lbs.)
Field Terminal Nuts . . . . . .2.8 N-m (25 in. lbs.)
BR IGNITION SYSTEM 8D -1
IGNITION SYSTEM
CONTENTS
page page
GENERAL INFORMATION CRANKSHAFT POSITION S E N S O R — 3 . 9 L / 5 . 2 L /

INTRODUCTION 2 5.9L ENGINE 11
DESCRIPTION AND OPERATION DISTRIBUTOR CAP—3.9L/5.2L/5.9L
AUTOMATIC SHUTDOWN (ASD) R E L A Y — ENGINES 11
3.9L/5.2L/5.9L ENGINES 4 DISTRIBUTOR ROTOR—3.9L/5.2L/5.9L
AUTOMATIC SHUTDOWN (ASD) R E L A Y — 8 . 0 L ENGINES 11
V-10 ENGINE 4 ENGINE COOLANT TEMPERATURE SENSOR . . 14
CAMSHAFT POSITION S E N S O R — 3 . 9 L / 5 . 2 L / FAILURE TO START TEST—3.9L/5.2L/5.9L
5.9L ENGINES 6 ENGINES 9
CAMSHAFT POSITION S E N S O R — 8 . 0 L V-10 IGNITION COIL PACK T E S T S — 8 . 0 L V-10
ENGINE 6 ENGINE 8
CRANKSHAFT POSITION S E N S O R — 3 . 9 L V-6 IGNITION COIL TEST—3.9L/5.2L/5.9L
ENGINE 4 ENGINES 8
CRANKSHAFT POSITION SENSOR—5.2L/5.9L IGNITION TIMING 11
V-8 ENGINES 4 INTAKE MANIFOLD AIR TEMPERATURE
CRANKSHAFT POSITION S E N S O R — 8 . 0 L V-10 SENSOR 14
ENGINE 5 MAP SENSOR 11
DISTRIBUTOR 3 SPARK PLUG CABLES 14
ENGINE COOLANT TEMPERATURE SENSOR . . . 6 SPARK PLUG CONDITIONS 15
IGNITION COIL PACKS—8.0L ENGINE 3 TESTING FOR SPARK AT COIL—3.9L/5.2L/
IGNITION COIL—3.9L/5.2L/5.9L ENGINES .... 3 5.9L ENGINES 7
IGNITION SWITCH AND KEY LOCK REMOVAL AND INSTALLATION
CYLINDER 7 AUTOMATIC SHUTDOWN (ASD) RELAY . . . . . 20
IGNITION S Y S T E M — 8 . 0 L V-10 ENGINE 2 CAMSHAFT POSITION S E N S O R — 3 . 9 L / 5 . 2 L /
IGNITION S Y S T E M — V - 6 / V - 8 ENGINES 2 5.9L ENGINES 23
INTAKE MANIFOLD AIR TEMPERATURE CAMSHAFT POSITION S E N S O R — 8 . 0 L V-10
SENSOR 7 ENGINE 23
MANIFOLD ABSOLUTE P R E S S U R E (MAP) COLUMN SHIFT INTERLOCK 30
SENSOR 6 CRANKSHAFT POSITION S E N S O R — 3 . 9 L / 5 . 2 L /
POWERTRAIN CONTROL MODULE 2 5.9L ENGINES 20
SPARK PLUG CABLES 3 CRANKSHAFT POSITION S E N S O R — 8 . 0 L V-10
SPARK PLUGS 3 ENGINE 22
THROTTLE POSITION SENSOR 6 DISTRIBUTORS 26
DIAGNOSIS AND TESTING ENGINE COOLANT TEMPERATURE SENSOR . . 25
AUTOMATIC SHUTDOWN (ASD) RELAY 7 IGNITION COIL PACKS—8.0L V-10 ENGINE . . 20
CAMSHAFT POSITION SENSOR T E S T — 8 . 0 L IGNITION COIL—3.9L/5.2L/5.9L ENGINES ... 19
V-10 ENGINE 13 IGNITION SWITCH AND KEY CYLINDER 27
CAMSHAFT POSITION S E N S O R — 3 . 9 L / 5 . 2 L / INTAKE MANIFOLD AIR TEMPERATURE
5.9L ENGINES 12 SENSOR 25
CRANKSHAFT POSITION SENSOR T E S T — MANIFOLD ABSOLUTE P R E S S U R E (MAP)
8.0L V-10 ENGINE 12 SENSOR 25
8D - 2 IGNITION SYSTEM
POWERTRAIN CONTROL MODULE (PCM) . . . 27 IGNITION COIL RESISTANCE—8.0L V-10

SPARK PLUG CABLES 17 ENGINE 32
SPARK PLUGS 18 IGNITION TIMING 30
THROTTLE POSITION SENSOR 25 SPARK PLUG CABLE O R D E R — 8 . 0 L V-10
SPECIFICATIONS ENGINE 31
ENGINE FIRING O R D E R — 3 . 9 L V-6 ENGINE . . 30 SPARK PLUG CABLE RESISTANCE 32
ENGINE FIRING ORDER—5.2L/5.9L V-8 SPARK PLUGS 31
ENGINES 30 TORQUE SPECIFICATIONS 31
IGNITION COIL RESISTANCE—3.9L/5.2L/5.9L VECI LABEL SPECIFICATIONS 30
ENGINES 32
G E N E R A L INFORMATION Camshaft Position, Throttle Position and MAP Sen

sors
INTRODUCTION
This group describes the ignition systems for 3.9L IGNITION SYSTEM—8.0L V-10 ENGINE
V-6, 5.2L/5.9L V-8, and 8.0L V-10 engines. The ignition system used on the 8.0L V-10 engine
The 3.9L V-6 and 5.2L V-8 engines will be referred will not use a conventional mechanical distributor. I t
to in this Ignition Group as: Light Duty Cycle (LDC) will be referred to as a distributor-less ignition sys
engines. The 5.9L V-8 gas powered engine will be tem. The ignition coils are individually fired, but
referred to as either: Light Duty Cycle (LDC) or each coil is a dual output. Refer to Ignition Coil Pack
Heavy Duty Cycle (HDC) engines. The 8.0L V-10 for additional information.
engine will be referred to as either: Light Duty Cycle The ignition system is controlled by the powertrain
(LDC) or Heavy Duty Cycle (HDC) engines. control module (PCM) on all engines.
Either of the HDC gas powered engines can be eas The ignition system consists of:
ily identified by the use of an engine mounted air • Spark Plugs
injection pump. The 3.9L V-6 engine, the 5.2/5.9L V-8 • Ignition Coil Packs containing individual coils
LDC or the 8.0L V-10 LDC gas engines will not use • Secondary Ignition Cables
an air injection pump. • Powertrain Control Module (PCM)
On Board Diagnostics is described in Group 25, • Also to be considered part of the ignition system
Emission Control Systems. are certain inputs from the Crankshaft Position,
Group 0, Lubrication and Maintenance, contains Camshaft Position, Throttle Position and MAP Sen
general maintenance information (in time or mileage sors
intervals) for ignition related items. The Owner's
Manual also contains maintenance information. POWERTRAIN CONTROL MODULE
The Powertrain Control Module (PCM) is located
in the engine compartment (Fig. 1).
D E S C R I P T I O N MMB O P E R A T I O N
IGNITION SYSTEM—V-6/V-8 ENGINES

The ignition systems used on the 3.9L V-6, the 5.2L
V-8 and the 5.9L V-8 are basically identical. Similar
ities and differences between the systems will be dis
cussed.
The ignition system is controlled by the powertrain
control module (PCM) on all engines.
The ignition system consists of:
• Spark Plugs
• Ignition Coil
• Secondary Ignition Cables
• Distributor (contains rotor and camshaft position
sensor)
• Powertrain Control Module (PCM)
• Also to be considered part of the ignition system
Fig. 1 Powertrain Control Module (PCM)
are certain inputs from the Crankshaft Position,
The ignition system is controlled by the PCM.
BR IGNITION SYSTEM 80 - 3

NOTE: On 3.9L/5.2L/5.9L engines, base ignition tim Although the d i s t r i b u t o r can be rotated, i t w i l l
ing by rotation of distributor is not adjustable. have no effect on i g n i t i o n timing.
All distributors contain an internal oil seal that
The PCM opens and closes the ignition coil ground prevents oil from entering the distributor housing.
circuit (or circuits) to operate the ignition coil (or coil The seal is not serviceable.
packs). This is done to adjust ignition timing, both
initial (base) and advance, and for changing engine SPARK PLUGS
operating conditions. All engines use resistor type spark plugs. Remove
The amount of electronic spark advance provided the spark plugs and examine them for burned elec
by the PCM is determined by five input factors: trodes and fouled, cracked or broken porcelain insu
engine coolant temperature, engine rpm, intake man lators. Keep plugs arranged in the order in which
ifold temperature, manifold "absolute pressure and they were removed from the engine. A single plug
throttle position. displaying an abnormal condition indicates that a
problem exists in the corresponding cylinder. Replace
DISTilBOTOfl . spark plugs at the intervals recommended in Group
All 3.9L V-6 and 5.2L/5.9L V-8 engines are O, Lubrication and Maintenance
equipped with a conventional camshaft driven Spark plugs that have low milage may be cleaned
mechanical distributor containing a shaft driven dis and reused i f not otherwise defective, carbon or oil
tributor rotor. The distributor is equipped with the fouled. Refer to- the Spark Plug Condition section of
camshaft position (fuel sync) sensor (Fig. 2). This this group.
sensor provides fuel injection synchronization and
cylinder identification. SPARK PLUG CABLES
Spark plug cables are sometimes referred to as sec
ondary ignition wires. These cables transfer electrical
current from the ignition coil(s) and/or distributor, to
individual spark plugs at each cylinder. The resistive
spark plug cables are of nonmetallic construction.
The cables provide suppression of radio frequency
emissions from the ignition system.
IGNITION COIL—3.9L/5.2L/5.9L ENGINES

Battery voltage is supplied to the ignition coil pos
itive terminal from the ASD relay.
The Powertrain Control Module (PCM) opens and
closes the ignition coil ground circuit for ignition coil
operation.
Base ignition timing is not adjustable on any
engine. By controlling the coil ground circuit, the
PCM is able to set the base timing and adjust the
Fig. 2 Distributor and Camshaft Position Sensor- ignition timing advance. This is done to meet chang
Typical ing engine operating conditions.
The distributor does not have,built in centrifugal The ignition coil is not oil filled. The windings are
or vacuum assisted advance. Base ignition timing embedded in an epoxy compound. This provides heat
and all timing advance is controlled by the Power- and vibration resistance that allows the ignition coil
train Control Module (PCM). Because ignition timing to be mounted on the engine.
is controlled by the PCM, base ignition t i m i n g is
not adjustable. IGNITION COIL PACKS—8.0L ENGINE
The distributor is held to the engine in the conven The ignition system used on the 8.0L V-10 engine
tional method using a holddown clamp and bolt. does not use a conventional mechanical distributor. I t
will be referred to as a distributor-less ignition sys
tem. Ignition timing is not adjustable on any
8.0L V-10 engine.
80 - 4 IGNITION SYSTEM
Two separate coil packs containing a total of five • The throttle position sensor
independent coils are attached to a common mount • Transmission gear selection
ing bracket located above the right engine valve
cover (Fig. 3). The coil packs are not oil filled. The AUTOMATIC SHUTDOWN (ASD) RELAY—3.9L/
front coil pack contains three independent epoxy 5.2L/5.9L ENGINES
filled coils. The rear coil pack contains two indepen As one of its functions, the ASD relay will supply bat
dent epoxy filled coils. tery voltage to the ignition coil. The ground circuit for
COILS
the ASD relay is controlled by the Powertrain Control
Module (PCM). The PCM regulates ASD relay operation
by switching the ground circuit on-and-off.
AUTOMATIC SHUTDOWN (ASi) RELAY—8.0L V-10

ENGINE
As one of its functions, the ASD relay will supply
battery voltage to each of the 5 independent ignition
coils. The ground circuit for the ASD relay is con
trolled by the Powertrain Control Module (PCM). The
PCM regulates ASD relay operation by switching the
ground circuit on-and-off.
ENGINE COIL
5
CRANKSHAFT POSITION SENSOR—3.9L V-6
-CYLINDER^ "MOUNTING
NUMBER BOLTS (8) J948D-6
ENGINE
Engine speed and crankshaft position are provided
Fig. 3 Ignition Coil Packs—8.0L V-10 Engine through the crankshaft position sensor. The sensor
generates pulses that are the input sent to the Pow
When one of the 5 independent coils discharges, i t ertrain Control Module (PCM). The PCM interprets
fires two paired cylinders at the same time (one cyl the sensor input to determine the crankshaft posi
inder on compression stroke and the other cylinder tion. The PCM then uses this position, along with
on exhaust stroke). other inputs, to determine injector sequence and igni
Coil firing is paired together on cylinders: tion timing.
• Number 5 and 10
The sensor is a hall effect device combined with an
• Number 9 and 8
internal magnet. I t is also sensitive to steel within a
• Number 1 and 6 certain distance from it.
• Number 7 and 4
The flywheel/drive plate has groups of notches at
• Number 3 and 2
its outer edge. On 3.9L V-6 engines, there are three
The ignition system is controlled by the powertrain sets of double notches and three sets of single
control module (PCM) on all engines. The PCM was notches (Fig. 4).
formerly referred to as the SBEC or engine control
The notches cause a pulse to be generated when
ler.
they pass under the sensor. The pulses are the input
The automatic shutdown (ASD) relay, after receiv to the PCM.
ing signals from the crankshaft and camshaft posi
The engine will not operate i f the PCM does not
tion sensors, will supply battery voltage to all of the
receive a crankshaft position sensor input.
ignition coil positive terminals. I f these signals are
not received by the PCM after approximately one sec CRANKSHAFT POSITION SENSOR—5.2L/5.9L V-8
ond of engine cranking (start-up), the ASD relay will
shut off positive voltage to all of the coils. Coil oper ENGINES
ation (firing) is then controlled by switching ground Engine speed and crankshaft position are provided
circuits (off-and-on) through the PCM. The PCM will through the crankshaft position sensor. The sensor
determine cylinder identification after receiving sig generates pulses that are the input sent to the Pow
nals from the crankshaft and camshaft position sen ertrain Control Module (PCM). The PCM interprets
sors. the sensor input to determine the crankshaft posi
The PCM adjusts ignition timing based on inputs it tion. The PCM then uses this position, along with
receives from: other inputs, to determine injector sequence and igni
• The engine coolant temperature sensor tion timing.
• The crankshaft position sensor (engine speed) The sensor is a hall effect device combined with an
• The manifold absolute pressure (MAP) sensor internal magnet. I t is also sensitive to steel within a
certain distance from it.
BR IGNITION SYSTEM 8D - 5

CRANKSHAFT CRANKSHAFT POSITION SENSOR—8.0L V-10
POSITION- ENGINE
SENSOR
The crankshaft position sensor is located on the
right-lower side of the cylinder block, forward of the
right engine mount, just above the oil pan rail (Fig.
6).
Fig. 4 Sensor Operation—3.9L Engine

Fig. 6 Crankshaft Position Sensor—8.0L V-10
On 5.2L and 5.9L ¥-8 engines, the flywheel/drive Engine
plate has 8 single notches, spaced every 45 degrees,
at its outer edge (Fig. 5). The crankshaft position sensor detects notches
The notches cause a pulse to be generated when machined into the middle of the crankshaft (Fig. 7).
they pass under the sensor. The pulses are the input
to the PCM. For each engine revolution, there are 8
pulses generated on V-8 engines.
receive a crankshaft position sensor input.
CRANKSHAFT
POSITION-
SENSOR
Fig. 7 Sensor Operation—8.0L V-10 Engine

There are five sets of notches. Each set contains
two notches. Basic ignition timing is determined by
the position of the last notch in each set of notches.
Once the powertrain control module (PCM) senses
the last notch, i t will determine crankshaft position
(which piston will next be at Top Dead Center). An
input from the camshaft position sensor is also
needed. I t may take the module up to one complete
engine revolution to determine crankshaft position
during engine cranking.
Fig. 5 Sensor Operation
1—5.2U5.9L Engine
8D - 6 IGNITION SYSTEM BR
The PCM uses the signal from the camshaft posi used to synchronize the fuel injectors with their
tion sensor to determine fuel injector sequence. Once respective cylinders. The sensor generates electrical
crankshaft position has been determined, the PCM pulses. These pulses (signals) are sent to the power-
begins energizing a ground circuit to each fuel injec train control module (PCM). The PCM will then
tor to provide injector operation. determine crankshaft position from both the cam
shaft position sensor and crankshaft position sensor.
CAMSHAFT POSITION SENSOR—3.9L/5.2L/5.9L A low and high area are machined into the cam
ENGINES shaft drive gear (Fig. 9). The sensor is positioned in
The camshaft position sensor is located in the dis the timing gear cover so that a small air gap (Fig. 9)
tributor on all engines. exists between the face of sensor and the high
The sensor contains a hall effect device called a machined area of cam gear.
sync signal generator to generate a fuel sync signal. When the cam gear is rotating, the sensor will
This sync signal generator detects a rotating pulse detect the machined low area. Input voltage from the
ring (shutter) on the distributor shaft. The pulse ring sensor to the PCM will then switch from a low
rotates 180 degrees through the sync signal genera (approximately 0.3 volts) to a high (approximately 5
tor. Its signal is used in conjunction with the crank volts). When the sensor detects the high machined
shaft position' sensor to differentiate between fuel area, the input voltage switches back low to approx
injection and spark events. I t is also used to synchro imately 0.3 volts.
nize the fuel injectors with their respective cylinders.
When the leading edge of the pulse ring (shutter)
CAM DRiWE LOW
enters the sync signal generator, the following occurs: MACHINED HIGH
The interruption of magnetic field causes the voltage GEAR
AREA MACHINED
to switch high resulting i n a sync signal of approxi AREA
mately 5 volts.
When the trailing edge of the pulse ring (shutter) CAMSHAFT
leaves the sync signal generator, the following occurs: POSITION
The change of the magnetic field causes the sync sig SENSOR
nal voltage to switch low to 0 volts.
CAMSHAFT POSITION SENSOR—8.0L V-10

ENGINE
The camshaft position sensor is located on the tim
ing chain case/cover on the left-front side of the
engine (Fig. 8).
CAMSHAFT
POSITION
SENSOR

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
For an operational description, diagnosis and
removal/installation procedures, refer to Group 14,
Fuel System.
ENGINE COOLANT TEMPERATURE SENSOR

For an operational description, diagnosis and
Fuel System.
Fig, 8 Camshaft Position Sensor Location—8.0L
V-10 Engine THROTTLE POSITION SENSOR
The camshaft position sensor is used in conjunction For an operational description, diagnosis and
with the crankshaft position sensor to differentiate removal/installation procedures, refer to Group 14,
between fuel injection and spark events. I t is also Fuel System.
INTAKE MANIFOLD AIR TEMPERATURE SENSOR loose (Fig. 11). Grasp the boot (not the cable) and
For an operational description, diagnosis and pull it off with a steady, even force.
Fuel System.
IGNITION SWITCH AND KEY LOCK CYLINDER

The ignition switch is located on the steering col
umn. The Key-In-Switch is located in the ignition
switch module. For diagnosis of the Key-In-Switch,
refer to Group, 8U.
A column shift interlock device is used to lock the
transmission shifter in the Park position when the
key is in the Off position. The interlock device is
located within the steering column assembly and is
not servicable. I f repair is necessary, the steering col
umn assembly must be replaced. Refer to Group 19,
Steering for procedures.
DIAGNOSIS AND TESTING Fig. 11 Cable Removal

(1) Disconnect the ignition coil secondary cable
AUTOMATIC SHUTDOWN (ASD) RELAY from center tower of the distributor cap. Hold the
The Automatic Shutdown (ASD) relay is located in cable terminal approximately 12 mm (1/2 in.) from a
the Power Distribution Center (PDC). The PDC is good engine ground (Fig. 12).
located in the engine compartment (Fig. 10). Refer to
label on PDC cover for relay location.
To perform a complete test of the ASD relay and its
related circuitry, refer to the appropriate Powertrain
Diagnostic Procedures service manual. To test the
relay only, refer to ASD and Fuel Pump Relays in
Group 14, Fuel System.
Fig. 12 Checking for Spark—Typical

WARNING: BE VERY CAREFUL WHEN THE
ENGINE IS CRANKING. DO NOT PUT YOUR HANDS
NEAR THE PULLEYS, BELTS OR THE FAN. DO NOT
WEAR LOOSE FITTING CLOTHING.
(2) Rotate (crank) the engine with the starter

motor and observe the cable terminal for a steady
Fig. 10 Power Distribution Center arc. I f steady arcing does not occur, inspect the sec
TESTING FOR SPARK AT COIL—3.9L/5.2L/5.9L ondary coil cable. Refer to Spark Plug Cables in this
group. Also inspect the distributor cap and rotor for
ENGINES
cracks or burn marks. Repair as necessary. I f steady
arcing occurs, connect ignition coil cable to the dis
CAUTION: When disconnecting a high voltage
tributor cap.
cable from a spark plug or from the distributor cap,
(3) Remove a cable from one spark plug.
twist the rubber boot slightly (1/2 turn) to break it
(4) Using insulated pliers, hold the cable terminal
approximately 12 mm (1/2 in.) from the engine cylin-
8D - 8 IGNITION SYSTEM • BR

der head or block while rotating the engine with the I f the ignition coil is being replaced, the secondary
starter motor. Observe the spark plug cable terminal spark plug cable must also be checked. Replace cable
for an arc. I f steady arcing occurs, i t can be expected if i t has been burned or damaged.
that the ignition secondary system is operating cor Arcing at the tower will carbonize the cable boot,
rectly ( I f the i g n i t i o n coil cable is removed for which i f i t is connected to a new ignition coil, will
this test, instead of a spark p l u g cable, the cause the coil to fail.
spark intensity w i l l be m u c h higher). I f steady I f the secondary coil cable shows any signs of dam
arcing occurs at the spark plug cables, but the engine age, i t should be replaced with a new cable and new
will not start,' connect the DRB scan tool. Refer to terminal. Carbon tracking on the old cable can cause
the appropriate Powertrain Diagnostic Procedures arcing and the failure of a new ignition coil. '
service manual.
IGNITION COIL PACI TESTS—8 J L ¥-18 ENGINE
IGNITION COIL TEST—3.9L/5.2L/5.9L ENGINES To perform a complete test of the ignition coil
To perform a complete test of the ignition coil and packs and their circuitry, refer to the DRB scan tool.
its circuitry, refer to the DRB scan tool. Also refer to Also refer to the appropriate Powertrain Diagnostics
the appropriate Powertrain Diagnostics Procedures Procedures manual. To test the coil packs only, refer
manual. To test the coil only, refer to the following: to the following procedure:
The ignition coil (Fig. 13) is designed to operate Two separate coil packs containing a total of five
without an external ballast resistor. independent coils are attached to a common mount
cover (Fig. 14). The coil packs are not oil filled. The
front coil pack contains three independent epoxy
filled coils that will fire six cylinders. The rear coil
pack contains two independent epoxy filled coils that
will fire four cylinders.
Fig. 13 ignition Coii (5.2L Shown)

Inspect the ignition coil for arcing. Test the coil
according to coil tester manufacturer's instructions.
Test the coil primary and secondary resistance.
Replace any coil that does not meet specifications.
Refer to the Ignition Coil Resistance chart.
Fig. 14 Ignition Coii Packs—8.0L V-10 Engine
P R I M A R Y RESISTANCE S E C O N D A R Y RESISTANCE
C O I L (MANUFACTURER) 21-27°C (70-80°F) 21-27°C (7§-8§°P)
Diamond 0.97- 1.18 Ohms 11,300- 15,300 Ohms
Toyodenso 0.95- 1.20 Ohms 11,300- 13,300 Ohms

J918D-2
IGNITION COIL RESISTANCE


To test the secondary resistance of each individual OHMMETER
paired coil, attach an ohmmeter across the coil tow
ers (Fig. 15) or (Fig. 16). This must be done between
corresponding cylinders number 3/2, 7/4, 1/6, 9/8 or MAKE OHMMETER
5/10 (Fig. 14). Refer to (Fig. 19) for resistance speci C O N N E C T I O N S AT
C O R R E S P O N D I N G CYLINDERS
fications. (5/10 OR 9/8).
To test the primary resistance of the front coil
pack, attach an ohmmeter between the B+ coil termi
nal and either the right (cylinders 3/2), center (cylin
ders 7/4) or left coil (cylinders 1/6) terminals (Fig.
17). Refer to (Fig. 19) for resistance specifications.
To test the primary resistance of the rear coil pack,
attach an ohmmeter between the B+ coii terminal FRONT
and either the right (cylinders 9/8) or left (cylinders OF
5/10) coil terminals (Fig. 18). Refer to (Fig. 19) for ENGINE
resistance specifications.
OHMMETER
MAKE OHMMETER J948D-15

C O N N E C T I O N S AT
C O R R E S P O N D I N G CYLINDERS
Fig. 16 Checking Coil Secondary Resistance—Rear
(1/6, 7/4 O R 3/2).
Coils—8.0L V-10 Engine
B+ TERMINAL
FRONT
OF
ENGINE
J948D-14
TO
CENTER
Fig. 15 Checking Coil Secondary Resistance—Front COIL J948D-16
Fig. 17 Checking Coil Primary Resistance—Front
FAILURE TO START TEST—3.9L/5.2L/5.9L
ENGINES
To prevent unnecessary diagnostic time and wrong (2) Connect a set of small jumper wires (18 gauge
test results, the Testing For Spark At Coil test or smaller) between the disconnected harness termi
should be performed prior to this test. nals and the ignition coil terminals. To determine
polarity at connector and coil, refer to the Wiring
WARNING: SET PARKING BRAKE OR BLOCK THE Diagrams section.
DRIVE WHEELS BEFORE PROCEEDING WITH THIS (3) Attach one lead of a voltmeter to the positive
TEST. (12 volt) jumper wire. Attach the negative side of
voltmeter to a good ground. Determine that sufficient
(1) Unplug the ignition coil harness connector at battery voltage (12.4 volts) is present for the starting
the coil (Fig. 13). and ignition systems.
80 - 10 IGNITION SYSTEM BR
TO LEFT TO RIGHT Check 32-way connectors for any spread terminals or
COIL COIL corrosion.
~~ POWERTRAI
CONTROL MODULE
FRONT
OF
ENGINE
B+
TERMINAL' J948D-17
Fig. 18 Checking Coii Primary Resistance—Rear

Coils—8.01 V-10 Engine
Fig. 20 PCM and Three 32-Way Connectors
* P r i m a r y Resistance: 0.53 to 0.65 ohms
- (6) Remove test lead from the coil positive terminal.
* * Secondary Resistance: 10.9 to 14.7 K ohms
Connect an 18 gauge jumper wire between the battery
Test across the primary connector.
positive terminal and the coil positive terminal.
Refer to text for test procedures. (7) Make the special jumper shown in (Fig. 21).
Using the jumper, momentarily ground the ignition
Test across the individual coil towers.
Refer to text for test procedures.
coil driver circuit at the PCM connector (cavity A-7).
For cavity/terminal location of this circuit, refer to
J948D-13 Group 8W, Wiring. A spark should be generated at
the coil cable when the ground is removed.
Fig. 19 Ignition Coil Resistance Specifications—8.0L
V-10 Engine CAPACITOR
(4) Determine that sufficient battery voltage (12.4

volts) is present for the starting and ignition sys GROUND
tems. THIS
(5) Crank the engine for 5 seconds while monitor CLIP
ing the voltage at the coil positive terminal:

• I f the voltage remains near zero during the
entire period of cranking, refer to On-Board Diagnos ALLIGATOR CLIP RBI003
tics in Group 14, Fuel Systems. Check the Power-
train Control Module (PCM) and auto shutdown Fig. 21 Special Jumper Ground-to-Coil Negative
relay. Terminal
• I f voltage is at or near battery voltage and drops
to zero after 1-2 seconds of cranking, check the pow (8) I f spark is generated, replace the PCM.
ertrain control module circuit. Refer to On-Board (9) I f spark is not seen, use the special jumper to
Diagnostics in Group 14, Fuel Systems. ground the coil negative terminal directly.
• I f voltage remains at or near battery voltage (10) I f spark is produced, repair wiring harness for
during the entire 5 seconds, turn the key off. Remove an open condition.
the three 32-way connectors (Fig. 20) from the PCM. (11) I f spark is not produced, replace the ignition
coil.
BR IGNITION SYSTEM 8D -11

DISTRIBUTOR CAP—3.9L/5.2L/5.9L ENGINES This is normal. Do not remove the charred com
Remove the distributor cap and wipe i t clean with pound. Test the spring for insufficient tension.
a dry lint free cloth. Visually inspect the cap for Replace a rotor that displays any of these adverse
cracks, carbon paths, broken towers or damaged conditions.
rotor button (Fig. 22) or (Fig. 23). - Also check for INSUFFICIENT
white deposits on the inside (caused by condensation SPRING
entering the cap through cracks). Replace any cap TENSION
that displays charred or eroded terminals. The
machined surface of a terminal end (faces toward
rotor) will indicate some evidence of erosion from
normal operation. Examine the terminal ends for evi
dence of mechanical interference with the rotor tip.
CORRODED EVIDENCE OF
PHYSICAL
CONTACT
WITH CAP J908D-48
Fig, 24 Rotor inspection—Typical

IGNITION TIMING
NOTE: Base (initial) ignition timing is NOT adjust

able on any engine. On 3.9L75.2L/5.9L engines, do
not attempt to adjust ignition timing by rotating the
distributor.
All ignition timing functions are controlled by the

Powertrain Control Module (PCM). The DRB scan
tool may be used to verify base timing and electronic
timing advance. Refer to the appropriate Powertrain
Diagnostics Procedures service manual for operation
of the DRB Scan Tool.
Fuel synchronization can be verified and set by
rotating the distributor. Refer to the Distributor
Removal/Installation section of this group. See
Checking Distributor Position. This operation can be
performed on 3.9L/5.2L/5.9L engines only.
MAP SENSOR
For an operational description, diagnosis or remov
Fig. 23 Cap inspection—internal—Typical al/ installation procedures, refer to Group 14, Fuel
Systems.
DISTRIBUTOR ROTOR—3 J L / I . 2 L / S J L ENGINES
Visually inspect the rotor (Fig. 24) for cracks, evi CRANKSHAFT POSITION SENSOR—3.9L/5.2L/5.9L
dence of corrosion or the effects of arcing on the
metal tip. Also check for evidence of mechanical ENGINE
interference with the cap. Some charring is normal To perform a complete test of this sensor and its
on the end of the metal tip. The silicone-dielectric- circuitry, refer to the DRB scan tool. Also refer to the
varnish-compound applied to the rotor tip for radio appropriate Powertrain Diagnostics Procedures man
interference noise suppression, will appear charred. ual. To test the sensor only, refer to the following:
80 - 1 2 IGNITION SYSTEM BR
DIAGNOSIS A N D T E S T I N G (Continued)
The sensor is located on the top of cylinder block
near the rear of right cylinder head (Fig. 25).
(1) Near the rear of the intake manifold, discon
nect sensor pigtail harness connector from main wir
ing harness.
Fig. 27 Crankshaft Position Sensor—8*01 ¥-10

Engine—Typical
To perform a complete test of this sensor and its
circuitry, refer to the DRB scan tool.. Also refer to the
appropriate Powertrain Diagnostics Procedures man
ual. To test the' sensor only, refer to the following:
(2) Disconnect the sensor pigtail harness from the
main engine wiring harness connector.
(3) Place an ohmmeter across terminals B and C
Fig, 25 Crankshaft Position. Sensor—Typical
(Fig. 26). Ohmmeter should be set to lK-to-lOK
(2) Place an ohmmeter across terminals B and C scale for this test. The meter reading should be
(Fig. 26). Ohmmeter should be set to lK-to-lOK scale open (no resistance). Replace sensor i f a low resis
for this test. The meter reading should be open (no tance is indicated.
resistance). Replace sensor i f a low resistance is indi
cated. CAMSHAFT POSITION SENSOR—3.9L/5.2L/5.9L
ENGINES
The camshaft position sensor is located in the dis
tributor (Fig. 28) on all engines.
VIEW LOOKING INTO

CPS CONNECTOR J938D-7
Fig. 26 Sensor Connector

CRANKSHAFT POSITION SENSOR TEST—8.0L
V-10 ENIINE
The crankshaft position sensor is located on the Fig, 28 Camshaft Position Sensor—Typical
right-lower side of the cylinder block, forward of the To perform a complete test of this sensor and its
right engine mount, just above the oil pan rail (Fig. circuitry, refer to the appropriate Powertrain Diag-
27).
en IGNITION SYSTEM 80 - 13
DIAGNOSIS AND TESTING fContinued!

nasties Procedures service manual. To test the sensor position sensor in the distributor is operating prop
only, refer to the following: erly and a sync pulse signal is being generated.
For this test, an analog (non-digital) voltme If sync pulse signal is not present, replacement of
ter is needed. Do not remove the distributor connec the camshaft position sensor is necessary
tor from the distributor. Using small paper clips,
insert them into the backside of the distributor wire CAMSHAFT POSITION SENSOR TEST—8.0L V-10
harness connector to make contact with the termi ENGINE
nals. Be sure that .the connector is not damaged The camshaft position sensor is located in the tim
when inserting the paper clips. Attach voltmeter ing chain case/cover on the left-front side of the
leads to these paper clips. engine (Fig. 29).
(1) Connect the positive (+) voltmeter lead into the
sensor output wire. This is at done the distributor
wire harness connector. For wire identification, refer
to Group 8W, Wiring Diagrams.
(2) Connect the negative (-) voltmeter lead into the
ground wire. For wire identification, refer to Group
8W, Wiring Diagrams.
(3) Set the voltmeter to the 15 Volt DC scale.
(4) Remove distributor cap from distributor (two
screws). Rotate (crank) the engine until the distribu
tor rotor is pointed towards the rear of vehicle. The
movable pulse ring should now be within the sensor
pickup.
(5) Turn ignition key to ON position. Voltmeter
should read approximately 5.0 volts. •
(6) I f voltage is not present, check the voltmeter
leads for a good connection.
Fig. 29 Camshaft Position Sensor—8.0L V-10 Engine
(7) I f voltage is still not present,. check for voltage
at the supply wire. For wire identification, refer to To perform a complete test of this sensor and its
Group 8W, Wiring Diagrams. circuitry, refer to the DRB scan tool. Also refer to the
(8) I f 5 volts is not present at supply wire, check appropriate Powertrain Diagnostics Procedures man
for voltage at PCM 32-way connector (cavity A-17). ual. To test the sensor only, refer to the following:
Refer to Group 8W, Wiring for location of connector/ (1) Disconnect the sensor connector at sensor.
terminal. Leave the PCM connector connected for (2) Place an ohmmeter across terminals B and C
this test. (Fig. 30). Ohmmeter should be set to lK-to-lOK
(9) I f voltage is still not present, perform vehicle scale for this test. The meter reading should be
test using the DRB scan tool. open (no resistance). Replace sensor i f a low resis
(10) I f voltage is present at cavity A-17, but not at tance is indicated.
the supply wire:
(a) . Check continuity between the supply wire. B+ GROUND OUTPUT
This is checked between the distributor connector
and cavity A-17 at the PCM. I f continuity Is not
present, repair the harness as necessary.
(b) Check for continuity between the camshaft
position sensor output wire and cavity A-18 at the
PCM. I f continuity is not present, repair the har
ness as necessary.
(c) Check for continuity between the ground cir
cuit wire at the distributor connector and ground.
If continuity is not present, repair the harness as
necessary.
(11) While observing the voltmeter, crank the
engine with Ignition switch. The voltmeter needle
should fluctuate between 0 and 5 volts while the
engine is cranking. This verifies that the camshaft
Fig. 30 Sensor Connector—8.0L Engine
8D 14 IGNITION SYSTEM BR
ENGINE COOLANT TEMPERATURE SENSOR ing. This may cause possible heat damage to the
For an operational description, diagnosis and catalytic converter. Total test time must not exceed
removal/installation procedures, refer to Group 14, ten minutes.
Fuel System.
With the engine running, remove spark plug cable
INTAKE MANIFOLD AIR TEMPERATURE SENSOR from spark plug (one at a time) and hold next to a
For an operational description, diagnosis and good engine ground. I f the cable and spark plug are
removal/installation procedures, refer to Group 14, in good condition, the engine rpm should drop and
Fuel System. the engine will run poorly. I f engine rpm does not
drop, the cable and/or spark plug may not be operat
SPARK PLUG CABLES ing properly and should be replaced. Also check
Check the spark plug cable connections for good engine cylinder compression.
contact at the coil(s), distributor cap towers, and With the engine not running, connect one end of a
spark plugs. Terminals should be fully seated. The test probe to a good ground. Start the engine and run
insulators should be in good condition and should fit the other end of the test probe along the entire
tightly on the coil, distributor and spark plugs. Spark length of all spark plug cables. I f cables are cracked
plug cables with insulators that are cracked or torn or punctured, there will be a noticeable spark jump
must be replaced. from the damaged area to the test probe. The cable
Clean high voltage ignition cables with a cloth running from the ignition coil to the distributor cap
moistened with a non-flammable solvent. Wipe the can be checked in the same manner. Cracked, dam
cables dry. Check for brittle or cracked insulation. aged or faulty cables should be replaced with resis
On 3.9L/5.2L/5.9L engines, spark plug cable heat tance type cable. This can be identified by the words
shields are pressed into the cylinder head to sur ELECTRONIC SUPPRESSION printed on the cable
round each spark plug cable boot and spark plug jacket.
(Fig. 31). These shields protect the spark plug boots Use an ohmmeter to test for open circuits, exces
from damage (due to intense engine heat generated sive resistance or loose terminals. I f equipped,
by the exhaust manifolds) and should not be remove the distributor cap from the distributor. Do
removed. After the spark plug cable has been not remove cables from cap. Remove cable from
installed, the lip of the cable boot should have a spark plug. Connect ohmmeter to spark plug termi
small air gap to the top of the heat shield (Fig. 31). nal end of cable and to corresponding electrode in
distributor cap. Resistance should be 250 to 1000
Ohms per inch of cable. I f not, remove cable from dis
tributor cap tower and connect ohmmeter to the ter
minal ends of cable. I f resistance is not within
specifications as found in the Spark Plug Cable
Resistance chart, replace the cable. Test all spark
plug cables in this manner.
MINIMUM MAXIMUM
250 Ohms Per Inch 1000 Ohms Per Inch
3000 Ohms Per Foot 12,000 Ohms Per Foot
J908D-43
SPARK PLUG CABLE RESISTANCE

To test ignition coil-to-distributor cap cable, do not
Fig. 31 Heat Shields—3.9U5.2U5.9L Engines remove the cable from the cap. Connect ohmmeter to
TESTING rotor button (center contact) of distributor cap and
When testing secondary cables for damage with an terminal at ignition coil end of cable. I f resistance is
oscilloscope, follow the instructions of the equipment not within specifications as found in the Spark Plug
manufacturer. Cable Resistance chart, remove the cable from the
If an oscilloscope is not available, spark plug cables distributor cap. Connect the ohmmeter to the termi
may be tested as follows: nal ends of the cable. If resistance is not within spec
ifications as found in the Spark Plug Cable
CAUTION: Do not leave any one spark plug cable Resistance chart, replace the cable. Inspect the igni
disconnected for longer than necessary during test tion coil tower for cracks, burns or corrosion.
BR IGNITION SYSTEM 80 - 1 5

SPARK PLUG CONDITIONS WET FOULING OR GAS FOULING
A spark plug coated with excessive wet fuel or oil
NORMAL OPERATING is wet fouled. In older engines, worn piston rings,
The few deposits present on the spark plug will leaking valve guide seals or excessive cylinder wear
probably be light tan or slightly gray in color. This is can cause wet fouling. I n new or recently overhauled
evident with most grades of commercial gasoline engines, wet fouling may occur before break-in (nor
(Fig. 32). There will not be evidence of electrode mal oil control) is achieved. This condition can usu
burning. Gap growth will not average more than ally be resolved by cleaning and reinstalling the
approximately 0.025 mm (.001 in) per 1600 km (1000 fouled plugs.
miles) of operation. Spark plugs that have normal
wear can usually be cleaned, have the electrodes OIL OR ASH ENCRUSTED
filed, have the gap set and then be installed. If one or more spark plugs are oil or oil ash
encrusted (Fig. 33), evaluate engine condition for the
NORMAL DRY BLACK COLD (CARBON) FOULING cause of oil entry into that particular combustion
chamber.
J908D-15
Fig. 32 Normal Operation and Cold (Carbon) Fouling

Some fuel refiners in several areas of the United
States have introduced a manganese additive (MMT)
for unleaded fuel. During combustion, fuel with MMT
causes the entire tip of the spark plug to be coated
with a rust colored deposit. This rust color can be
misdiagnosed as being caused by coolant in the com PR!673
bustion chamber. Spark plug performance is not
affected by MMT deposits. Fig. 33 Oil or Ash Encrusted
COLD FOULING/CARBON FOULING ELSCWmOmE GAP BRIDGING

Cold fouling is sometimes referred to as carbon Electrode gap bridging may be traced to loose
fouling. The deposits that cause cold fouling are basi deposits i n the combustion chamber. These deposits
cally carbon (Fig. 32). A dry, black deposit on one or accumulate on the spark plugs during continuous
two plugs in a set may be caused by sticking valves stop-and-go driving. When the engine is suddenly
or defective spark plug cables. Cold (carbon) fouling subjected to a high torque load, deposits partially liq
of the entire set of spark plugs may be caused by a uefy and bridge the gap between electrodes (Fig. 34).
clogged air cleaner element or repeated short operat This short circuits the electrodes. Spark plugs with
ing times (short trips). electrode gap bridging can be cleaned using standard
procedures.
8D - 16 IGNITION SYSTEM _ — _ - _ ' rs^ro)

GROUND GROUND
ELECTRODE
J908D-11 J908D-13
Fig. 34 Electrode Gap Bridging Fig. 36 Chipped Electrode Insulator

SCAVENGER DEPOSITS PREMONITION DAMAGE
Fuel scavenger deposits may be either white or yel Preignition damage is usually caused by excessive
low (Fig. 35). They may appear to be harmful, but combustion chamber temperature. The center elec
this is a normal condition caused by chemical addi trode dissolves first and the ground electrode dis
tives in certain fuels. These additives are designed to solves somewhat latter (Fig. 37). Insulators appear
change the chemical nature of deposits and decrease relatively deposit free. Determine i f the spark plug
spark plug misfire tendencies. Notice that accumula has the correct heat range rating for the engine.
tion on the ground electrode and shell area may be Determine i f ignition timing is over advanced or i f
heavy, but the deposits are easily removed. Spark other operating conditions are causing engine over
plugs with scavenger deposits can be considered nor heating. (The heat range rating refers to the operat
mal in condition and can be cleaned using standard ing temperature of a particular type spark plug.
procedures. Spark plugs are designed to operate within specific
temperature ranges. This depends upon the thick
GROUND
ness and length of the center electrodes porcelain
ELECTRODE
COVERED insulator.)
GROUND
ELECTRODE
CENTER
ELECTRODE
DISSOLVED
J908D-12
Fig. 35 Scavenger Deposits

CHIPPED ELECTRODE INSULATOR J908D-14
A chipped electrode insulator usually results from

Fig. 37 Preignition Damage
bending the center electrode while adjusting the
spark plug electrode gap. Under certain conditions,
severe detonation can also separate the insulator
from the center electrode (Fig. 36). Spark plugs with
this condition must be replaced.
BR IGNITION SYSTEM 8D - 1 7

SPARK PLUG OVERHEATING Install cables into the proper engine cylinder firing
Overheating is indicated by a white or gray center order (Fig. 40), (Fig. 41) or (Fig. 42).
electrode Insulator that also appears blistered (Fig.
38). The Increase in electrode gap. will be consider
ably in excess of 0.001 inch per 1000 miles of opera
tion. This suggests - that a plug with a cooler heat
range rating should be used. Over advanced ignition
timing, detonation and cooling system malfunctions
can also cause spark plug overheating.
BLISTERED
WHITE OR
o
FRONT
CLOCKWISE ROTATION
1-6-5-4-3-2
OF
GRAY ENGINE
COLORED
INSULATOR
J9314-80
Fig. 40 Engine Firing Order—3.9 L V-6 Engine
J906D-16
Fig. 38 Spark Plug Overheating

REMOVAL AND INSTALLATION oFRONT
CLOCKWISE ROTATION
1-8-4-3-6-5-7-2
SPARK PLUG CABLES OF

ENGINE
CAUTION; When disconnecting a high voltage

cable from a spark plug or from the distributor cap,
twist the rubber boot slightly (1/2 turn) to break it
loose (Fig. 39). Grasp the boot (not the cable) and J9314-79
pull it off with a steady, even force.

Fig. 41 Engine Firing Order—5.2U5.9L V-8 Engines
SPARK PLUG BOOT * When replacing the spark plug and coil cables,
PULLER route the cables correctly and secure in the proper
retainers. Failure to route the cables properly can
SPARK PLUG cause the radio to reproduce ignition noise. I t could
CABLE A N D also cause cross ignition of the plugs or short circuit
BOOT
the cables to ground.
When installing new cables, make sure a positive
connection is made. A snap should be felt when a
good connection is made between the plug cable and
the distributor cap tower.
TWIST A N D PULL
SPARK PLUG 958D-9
Fig. 39 Cable Removal

REAR COIL PACK FRONT COIL PACK PLUG REMOVAL
(1) Always remove spark plug or ignition coil
cables by grasping at the cable boot (Fig. 39). Turn
the cable boot 1/2 turn and pull straight back i n a
steady motion. Never pull directly on the cable.
Internal damage to cable will result.
(2) Prior to removing the spark plug, spray com
pressed air around the spark plug hole and the area
around the spark plug. This will help prevent foreign
material from entering the combustion chamber.
(3) Remove the spark plug using a quality socket
with a rubber or foam insert.
(4) Inspect the spark plug condition. Refer to
Spark Plug Condition in the Diagnostics and Testing
section of this group.
PLUG GLEANING
The plugs may be cleaned using commercially
available spark plug cleaning equipment. After clean
ing, file the center electrode flat with a small point
file or jewelers file before adjusting gap.
CAUTION: Never use a motorized wire wheel brush

to clean the spark plugs. Metallic deposits will
RIGHT LEFT
remain on the spark plug insulator and will cause
BANK SANK plug misfire.
FIRING ORDER
I.IO.9.4.3-6-5-8.7.2 J 948D-12
PLUG GAP ADJUSTMENT
Fig. 42 Spark Plug Cable Order—8.0L ¥-10 Engine Check the spark plug gap with a gap gauge tool. I f
SPARK PLUGS the gap is not correct, adjust i t by bending the
On 3.9L/5.2L/5.9L engines, spark plug cable heat ground electrode (Fig. 44). Never attempt to adjust
shields are pressed into the cylinder head to sur the gap by bending the center electrode.
round each cable boot and spark plug (Fig. 43).
GAUGE
SPARK
PLUG
J9314-94
Fig. 48 Heat Shields—3.9U5.2U5.9L Engines
If removal of the heat- shield(s) is necessary,
remove the spark plug cable and compress the sides
of shield for removal. Each shield is slotted to allow J908D-10
for compression and removal. To install the shields,
align shield to machined opening in cylinder head Fig. 44 Setting Spark Plug Gap—Typical
and tap Into place with a block of wood.
BR — — — — ^ — - IGNITION SYSTEM 80 - 1 9

SPARE PLUG GAP
3.9L/5.2L/5.9L Engines: .89 mm (.035 in).
8.0L Engine; 1.14 mm (.045 in).
PLUG INSTALLATION
Special care should be taken when installing spark
plugs into the cylinder head spark plug wells. Be
sure the plugs do not drop into the plug wells as elec
trodes can be damaged.
Always tighten spark plugs to the specified torque.
Over tightening can cause distortion resulting in a
change in the spark plug gap or a cracked porcelain
Insulator.
When replacing the spark plug and ignition coil
cables, route the cables correctly and secure them in
the appropriate retainers. Failure to route the cables
properly can cause the radio to reproduce ignition
Fig. 45 Ignition Coil—3.9L V-6 or 5.2/5.9L V-8
noise. It could cause cross ignition of the spark plugs
LDC-Gas Engines
or short circuit the cables to, ground.
(1) Start the spark plug into the cylinder head by
hand to avoid cross threading.
(2) Tighten spark plugs to 35-41 N-m (26-30 ft.
lbs.) torque.
(3) Install spark plug cables over spark plugs.
IGNITION COIL—3.9L/5.2L/5.9L ENGINES

The ignition coil is an epoxy filled type. I f the coil
is replaced, i t must be replaced with the same type.
REMOVAL
3.9L V-6 or 5.2/5.9L V-8 LDC-Gas Engines: The coil
is mounted to a bracket that is bolted to the front of
the right engine cylinder head (Fig. 45). This bracket
is mounted on top of the automatic belt tensioner
bracket using common bolts. -
5.9L V-8 HDC-Gas Engine: The coil is mounted to Fig. 46 Ignition Coil—5.9L V-8 HDC-Gas Engine
a bracket that is bolted to the air injection pump THE BELT SECTION OF GROUP 7, COOLING SYS
(AIR pump) mounting bracket (Fig. 46). TEM.
(1) Disconnect the primary wiring from the igni
tion coil. (3) Remove ignition coil from coil mounting
(2) Disconnect the secondary spark plug cable from bracket (two bolts).
the ignition coll.
INSTALLATION
WARNING; 3.9L ¥-6 OR 5.2/5.9L ¥-8 LDC-GAS (1) Install the ignition coil to coil bracket. I f nuts
ENGINES; DO NOT REMOVE THE COIL MOUNTING and bolts are used to secure coil to coil bracket,
BRACKET-TO-CYLINDER HEAD MOUNTING BOLTS. tighten to 11 N-m (100 in. lbs.) torque. I f the coil
THE COIL MOUNTING BRACKET IS UNDER ACCES mounting bracket has been tapped for coil mounting
SORY DRIVE BELT TENSION. IF THIS BRACKET IS bolts, tighten bolts to 5 N-m (50 in. lbs.) torque.
TO BE REMOVED FOR ANY REASON, A L L BELT (2) Connect all wiring to ignition coil.
TENSION MUST FIRST BE RELIEVED. REFER TO
R E M O V A L AND INSTALLATION ( C o n t i n u e d )
IGNITION COIL PACKS—8.GL V-10 ENGINE R E A R C O I L PACK FRONT COIL PACK
REMOVAL
Two separate coil packs containing a total of five
Independent coils are attached to a common mount
cover (Fig. 47). The front and rear coil packs can be
serviced separately.
ENGINE COIL
CYLINDER^ "MOUNTING'
" NUMBER BOLTS (8) J948D-6
RIGHT LEFT
Fig. 47 ignition Coii Packs—8*01 ¥-10 Engine BANK BANK
(1) Remove the secondary spark plug cables from FIRING ORDER
1-10.9-4-3-6-5-8-7-2 J948D-12
the coil packs. Note position of cables before removal.
(2) Disconnect the primary wiring harness connec
tors at coil packs. Fig. 48 Spark Plug Cable Order—8.0L ¥-10 Engine
(3) Remove the four (4) coil pack-to-coil mounting POWER
bracket bolts for the coil pack being serviced (Fig. DISTRIBUTION
CENTER
47).
(PDC)
(4) Remove coil(s) from mounting bracket.
INSTALLATION
(1) Position coil packs to mounting bracket (prima
ry wiring connectors face downward).
(2) Install coil pack mounting bolts. Tighten bolts
to 10 N-m (90 in. lbs.) torque.
(3) Install coil pack-to-engine mounting bracket (if
necessary).
(4) Connect primary wiring connectors to coil
packs (four wire connector to front coil pack and
three wire connector to rear coil pack).
J9414-10
(5) Connect secondary spark plug cables to coil
packs. Refer to (Fig. 48) for correct cable order.
AUTOMATIC SHUTDOWN (ASD) 1ELAY CRANKSHAFT POSITION SENSOR—3.91/5.2L/5.9L
The Automatic Shutdown (ASD) relay is located in ENGINES
the Power Distribution Center (PDC). The PDC is
located in the engine compartment (Fig. 49). Refer to REMOVAL—EXCEPT 5.9L HDC ENGINE
label on PDC cover for relay location. Check the ter Use the following procedure i f engine is not
minals in the PDC relay connector for corrosion or equipped with an EGR system.
damage before installation.
REMOVAL AND I N S T A L L A T I O N fContinued)

The sensor is bolted to the top of the cylinder block
near the rear of right cylinder head (Fig, 50).
Fig. 51 Crankshaft Position Sensor—5.9L HDC ¥-8

Engine
Fig. 50 Crankshaft Position Sensor—Except 5.91
HDC Engine (5) Remove 2 EGR valve mounting bolts and
remove EGR valve. Discard old EGR gasket.
(1) Remove the air cleaner Intake tube. (6) Disconnect electrical connector at engine oil
(2) Disconnect crankshaft position sensor pigtail pressure sending unit.
harness from main wiring harness. (7) To prevent damage to oil pressure sending unit,
(8) Remove two sensor (recessed hex head) mount a special tool, such as number C-4597 must be used
ing bolts (Fig. 50). (Fig. 52). Remove sending unit from engine.
(4) Remove sensor from engine.
INSTALLATION—EXCEPT 5 . 9 L NBC ENGINE

(1) Position crankshaft position sensor to engine.
(2) Install mounting bolts and tighten to 8 N-m (70
in. lbs.) torque.
(3) Connect main harness electrical connector to sensor.
(4) Install air cleaner tube.
REMOVAL—5.9L HOC ENGINE

Use the following procedure If the 5.9L HDC
engine Is equipped with an EGR system.
The sensor is bolted to the top of the cylinder block
near the rear of right cylinder head (Fig. 51).
(1) Remove the air cleaner assembly and its plastic
air intake tube.
(2) Remove the spark plug cable loom and spark
plug cables from valve cover mounting stud at rear of
right valve cover (Fig. 51). Position spark plug cables
to top of valve cover.
(3) Disconnect 2 hoses at Exhaust Gas Recircula
tion (EGR) valve. Note position of hoses at EGR
valve before removal.
(4) Disconnect electrical connector and hoses at Fig. 52 Oil Pressure Sending Unit—Removal/
electric EGR valve control. Note position of hoses Installation
before removal.
8D - 22 IGM1TI0SSS SYSTEM BR
R E M O V A L A N D INSTALLATION fContinued)
(8) Loosen EGR tube mounting nut at Intake man
ifold.
(9) Remove 2 EGR tube mounting bolts at exhaust
manifold and remove EGR tube. Discard old gasket
at exhaust manifold.
(10) Disconnect crankshaft position sensor pigtail
harness from main wiring harness.
(11) Remove 2 sensor (recessed hex head) mount
ing bolts and remove sensor.
INSTALLATION—5.91 HOC ENGINE

' (1) Position crankshaft position sensor to engine
and Install mounting bolts. Tighten bolts to 8 N-m
(2) Connect main harness electrical connector to
sensor.
(3) Clean the EGR tube and exhaust- manifold (at
EGR tube mounting point) of any old gasket mate
rial.
(4) Install a new gasket to exhaust manifold end of
EGR tube and install EGR tube to both manifolds.
Tighten mounting nut at intake manifold. Tighten 2
mounting bolts at exhaust manifold to 23 N-m (204
in. lbs.) torque.
(5) Coat the threads of the oil pressure sending
unit with thread sealant. Do not allow any of the
thread sealant to get Into the' sending unit opening,
or the opening at the engine. Install sending unit to
engine and tighten to 14 N-m (130 in, lbs.) torque,
install electrical connector to sending unit.
(6) Clean the intake manifold and EGR valve of
any old gasket material.
(7) Install a new EGR valve gasket at intake man S E N S O R POSITIONED
ifold. FLUSH TO CYLINDER BLOCK J948D-2
(8) Install EGR valve to intake manifold. Tighten
2 bolts, to 23 N-m (200 in. lbs.) torque. Fig. 54 Sensor Removal/Installation—8.0L ¥-10
(9) Position EGR valve control and install its elec Engine
trical connector.* Connect hoses between EGR valve (5) Remove the sensor from vehicle.
and EGR valve control. Connect hose between main (6) Check condition of sensor o-ring (Fig. 55).
vacuum harness and control valve.
(10) Install spark plug cable loom and spark plug CRANKSHAFT
POSITION
cables to valve cover mounting stud.
(11) Install the air cleaner housing and plastic air
Intake tube.
CRANKSHAFT POSITION SENSOR—8.0L V-10

ENGINE
The crankshaft position sensor is located on the right-
lower side of the cylinder block, forward of the right
engine mount, just above the oil pan rail (Fig. 53).
REMOVAL
(2) Disconnect the sensor harness connectors.
(3) Remove the sensor mounting bolt (Fig. 54). J948D-3
(4) Carefully pry the sensor from the cylinder block
in a rocking action with two small screwdrivers. Fig. 55 Sensor O-Ring—8.0L ¥-10 Engine

INSTALLATION (8) Install rotor.
(1) Apply a small amount of engine oil to the sen (4) install distributor • cap. Tighten mounting
sor o-ring (Fig. 55). screws. -
(2) Install the sensor Into the cylinder block with a (5) install air cleaner assembly.
slight rocking action. Do not twist the sensor into
position as damage to the o- ring may result. CAMSHAFT POSITION SENSOR—8.0L V-10 ENGINE
The camshaft position sensor is located on the tim
CAUTION: Before tightening the sensor mounting ing chain case/cover on the left-front side of the
bolt, be sure the sensor is completely flush to the engine (Fig. 57).
cylinder block (Fig. 54). If sensor is not flush, dam
age to the sensor mounting tang may result.
(3) install the mounting bolt and tighten to 8 N-m

(4) Connect sensor wiring harness and lower the
vehicle.
CAMSHAFT POSITION SENSOR—3.9L/5.2L/5.9L

ENGINES
The camshaft position sensor is located in the dis
tributor (Fig. 56).
REMOVAL
Distributor removal is not necessary to remove
camshaft position sensor.
Fig. 57 Camshaft Position Sensor Location—8.0L

V-10 Engine
A thin plastic rib is molded Into the face of the sen
sor (Fig. 58) to position the depth of sensor to the
upper cam gear (sprocket). This rib can be found on
both the new replacement sensors and sensors that
were originally installed to the engine. The first time
the engine has been operated, part of this rib may be
sheared (ground) off. Depending on parts tolerances,
some of the rib material may still be observed after
removal.
CAMSHAFT
Fig, 56 Camshaft Position Sensor—•Typical

(1) Remove air cleaner assembly.
(2) Disconnect negative cable from battery.
(3) Remove distributor cap from distributor (two
screws).
(4) Disconnect camshaft position sensor wiring
harness from main engine wiring harness.
(5) Remove distributor rotor from distributor shaft.
(6) Lift the camshaft position sensor assembly RIB MATERIAL
from the distributor housing (Fig. 56). (FOR SENSOR DEPTH POSITIONING)
INSTALLATION Fig. 58 Sensor Depth Positioning Rib—8.0L V-10

(1) Install camshaft position sensor to distributor.
Engine
Align sensor into notch on distributor housing.
(2) Connect wiring harness.
Refer to either of the following procedures, Sensor A low and high area are machined into the cam
Removal—Replacing Old Sensor With Original, or shaft drive gear (Fig. 60). The sensor is positioned i n
Sensor Removal—Replacing With New Sensor: the timing gear cover so that a small air gap (Fig.
60) exists between the face of sensor and the high
SENSOR REMOVAL—REPLACING OLD machined area of cam gear.
SENSOR WITH ORIGINAL
If the original camshaft position sensor is to be
removed and installed, such as when servicing the CAM DRIVE LOW
timing chain, timing gears or timing chain cover, use GEAR MACHINED HIGH
this procedure. AREA MACHINED
(1) Disconnect the sensor harness connector from AREA
the sensor.
(2) Remove the sensor mounting bolt (Fig. 57). CAMSHAFT
(3) Carefully pry the sensor from the timing chain POSITION
SENSOR
case/cover in a rocking action with two small screw
drivers.
(4) Remove the sensor from vehicle.
(5) Check condition of sensor o-ring (Fig. 59).
SLOTTED SCRIBE
DUNTII LINE
HOLE
CAMSHAFT
POSITION
SENSOR O-RING

Before the sensor is installed, the cam gear may
have to be rotated. This is to allow the high
machined area on the gear to be directly in front of
the sensor mounting hole opening on the timing gear
cover.
Do not install sensor with gear positioned at
Fig. 59 Camshaft Sensor O-Ring—8.0L ¥-10 Engine
low area (Fig. 61) or (Fig. 60). When the engine
INSTALLATION is started, the sensor will be broken.
When installing a used camshaft position sensor, (5) Using a 1/2 in. wide metal ruler, measure the
the sensor depth must be adjusted to prevent contact distance from the cam gear to the face of the sensor
with the camshaft gear (sprocket). mounting hole opening on the timing gear cover (Fig.
. (1) Observe the face of the sensor. I f any of the 61). '
original rib material remains (Fig. 58), it must be cut (6) I f the dimension is approximately 1.818 inches,
down flush to the face of the sensor with a razor it is OK to install sensor. Proceed to step Step 9.
knife. Remove only enough of the rib material until (7) I f the dimension is approximately 2.018 inches,
the face of the sensor is flat. Do not remove more the cam gear will have to be rotated.
material than necessary as damage to sensor may (8) Attach a socket to the vibration damper mount
result. Due to a high magnetic field and possible elec ing bolt and rotate engine until the 1.818 inch
trical damage to the sensor, never use an electric dimension is attained.
grinder to remove material from sensor. (9) Install the sensor into the timing case/cover
(2) From the parts department, obtain a peel-and- with a slight rocking action until the paper spacer
stick paper spacer (Fig. 58). These, special paper contacts the camshaft gear. Do not install the sensor
spacers are of a certain thickness and are to be used mounting bolt. Do not twist the sensor into position
as a tool to set sensor depth. as damage to the o-ring or tearing of the paper
(3) Clean the face of sensor and apply paper spacer may result.
spacer (Fig. 58). (10) Scratch a scribe line into the timing chain
(4) Apply a small amount of engine oil to the sen case/cover to indicate depth of sensor (Fig. 59).
sor o-ring (Fig. 59).
IGNITION SYSTEM 8 1 - 25

LOW MACHINED 2.018" DO NOT 60) exists between the face of sensor and the high
AREA INSTALL SENSOR machined area of cam gear.
Before the sensor is installed, the cam gear may
have to be rotated. This is to allow the high
machined area on the gear to be directly in front of
the sensor mounting hole opening on the timing gear
cover.
Do not install sensor with gear positioned at
low area (Fig. 61) or (Fig. 60). When the engine
is started, the sensor will be broken.
(2) Using a 1/2 in. wide metal ruler, measure the
distance from the cam gear to the face of the sensor
mounting hole opening on the timing gear cover (Fig.
61) .
(3) I f the dimension is approximately 1.818 inches,
it is OK to install sensor. Proceed to step Step 9.
(4) I f the dimension is approximately 2.018 inches,
the cam gear will have to be rotated.
(5) Attach a socket to the vibration damper mount
ing bolt and rotate engine until the 1.818 inch
dimension is attained.
(6) Install the sensor into the timing case/cover
Fig. 61 Sensor Depth Dimensions with a slight rocking action. Do not twist the sensor
(11) Remove the sensor from timing chain case/ into position as damage to the o-ring may result.
cover. Push the sensor all the way into the cover until the
(12) Remove the paper spacer from the sensor. rib material on the sensor (Fig. 58) contacts the cam
This step must be followed to prevent the paper shaft gear.
spacer from getting into the engine lubrication sys (7) Install the mounting bolt and tighten to 6 N-m
tem. (50 in. lbs.) torque.
(13) Again, apply a small amount of engine oil to (8) Connect sensor wiring harness to engine har
sensor o-ring. ness.
(14) Again, install the sensor into the timing case/ When the engine is started, the rib material will be
cover with a slight rocking action until the sensor is sheared off the face of sensor. This will automatically
aligned to scribe line. set sensor air gap.
(15) Install sensor mounting bolt and tighten to 6
• For removal and installation, refer to Manifold
(16) Connect engine wiring harness to sensor.
Absolute Pressure Sensor in group 14, Fuel Systems.
SENSOR REMOVAL—REPLACING WITH NEW
SENSOR ENGINE COOLANT TEMPERATURE SENSOR
I f a new replacement camshaft position sensor is to For an operational description, diagnosis and
be installed, use this procedure. removal/installation procedures, refer to Group 14,
(1) Disconnect the sensor wiring harness connector Fuel System.
from sensor.
(2) Remove the sensor mounting bolt (Fig. 57). THROTTLE POSITION SENSOR
(3) Carefully pry the sensor from the timing chain For an operational description, diagnosis and
case/cover in a rocking action with two small screw removal/installation procedures, refer to Group 14,
drivers. Fuel System.
(4) Remove the sensor from vehicle.
INTAKE MANIFOLD AIR TEMPEftATOiE SENSOi
INSTALLATION For an operational . description, diagnosis and
(1) Apply a small amount of engine oil to the sen removal/installation procedures, refer to Group 14,
sor o-ring (Fig. 59). Fuel System.
A low and high area are machined into the cam
shaft drive gear (Fig. 60). The sensor is positioned i n
the timing gear cover so that a small air gap (Fig.
8D - 28 IGNITION S \ „,..... _ _ _ _ _ _ BR
R E M O V A L AND BNSYALLATION ( C o n t i n u e d )
DISTRIBUTORS
REMOVAL
CAUTION: Base ignition timing is not adjustable

on any engine. Distributors do not have built in
centrifugal or vacuum assisted advance. Base igni
tion t i m i n g and timing advance are controlled by
the Powertrain Control Module (PCM). Because a
conventional timing light can not be used t o adjust
distributor position after installation, note position
of distributor before removal.

(2) Disconnect negative cable from battery.
DISTRIBUTOR J9314-81
• (3) Remove distributor cap from distributor (two
screws). Fig. 83 Rotor Alignment Mark
(4) Mark the position of distributor housing in
relationship to engine or dash panel. This is done to (10) Remove distributor rotor from distributor
aid in installation. shaft.
(5) Before distributor is removed, the number one (11) Remove distributor holddown clamp bolt and
cylinder must be brought t o t h e Top D e a d Center clamp (Fig. 64). Remove distributor from vehicle.
(TDC) firing position.
(6) Attach a socket to the Crankshaft Vibration
Damper mounting bolt.
(7) Slowly rotate engine clockwise, as viewed from
front, until indicating mark on crankshaft vibration
damper is aligned to 0 degree (TDC) mark on timing
chain cover (Fig. 82).
Fig. 64 Distributor Holddown Clamp

CAUTION: Do not crank engine with distributor
removed. Distributor/crankshaft relationship will be
lost.
INSTALLATION
Fig. 62 Damper-To-Cover Alignment Marks—Typical I f engine lias been cranked while distributor is
removed, establish the relationship between distribu
• (8) The distributor rotor should now be aligned to tor shaft and number one piston position as follows:
the CYL. NO. 1 alignment mark (stamped) into the Rotate crankshaft in a clockwise direction, as
camshaft position sensor (Fig. 63). i f not, rotate the viewed from front, until,number one cylinder piston
crankshaft through another complete 360 degree is at t o p o f compression stroke (compression should
turn. Note the position of the number one cylinder be felt on finger with number one spark plug
spark plug cable (on the cap) in relation to rotor. removed). Then * continue to slowly rotate engine
Rotor should now be aligned to this position. clockwise until Indicating mark (Fig. 62) is aligned to
(9) Disconnect camshaft position sensor wiring 0 degree (TDC) mark on timing chain cover.
harness from main engine wiring harness.

(1) Clean top of cylinder block for a good seal The degree scale on the SET SYNC screen of the
between distributor base and block. DRB is referring to fuel synchronization only. It is
(2) Lightly oil the rubber o-ring seal on the distrib not referring to ignition timing. Because of this,
utor housing. do not attempt to adjust ignition timing using this
(3) Install rotor to distributor shaft. method. Rotating the distributor will have no effect
(4) Position distributor into engine to its original on ignition timing. All ignition timing values are con
position. Engage tongue of distributor shaft with slot trolled by the powertrain control module (PCM).
in distributor oil pump drive gear. Position rotor to After testing, install air cleaner assembly.
the number one spark plug cable position.
(5) Install distributor holddown clamp and clamp POWERTRAIN CONTROL MODULE (PCM)
bolt. Do not tighten bolt at this time. Refer to Group 14, Fuel System for procedures.
(6) Rotate the distributor housing until rotor is
aligned to CYL. NO. 1 alignment mark on the cam IGNITION SWITCH AND KEY CYLINDER
shaft position sensor (Fig. 63). The ignition switch is located on the steering col
(7) Tighten clamp holddown bolt (Fig. 64) to 22.5 umn. The Key-In-Switch is located i n the ignition
N-m (200 in. lbs.) torque. switch module. For diagnosis of the Key-In-Switch,
(8) Connect camshaft position sensor wiring har refer to Section 8U.
ness to main engine harness.
(9) Install distributor cap. Tighten mounting REMOVAL
screws. (1) Disconnect negative cable from battery.
(10) Refer to the following, Checking Distributor (2) I f vehicle has a tilt column, remove tilt lever by
Position. turning it counterclockwise.
(3) Remove upper and lower covers from steering
CHECKING DISTRIBUTOR POSITION column (Fig. 65).
To verify correct distributor rotational position, STEERING TILT UPPER PANEL
connect the DRB scan tool to the data link connector. WHEEL LEVER SHROUD BRACKET
The data link connector is located in the engine com
partment. Gain access to the SET SYNC screen on
the DRB.
WARNING: WHEN PERFORMING THE FOLLOWING

TEST, THE ENGINE WILL BE RUNNING. BE CARE
FUL NOT TO STAND IN LINE WITH THE FAN
BLADES OR FAN BELT. DO NOT WEAR LOOSE
CLOTHING.
Follow the directions on the DRB screen and start

the engine. With the engine running, the words I N
RANGE should appear on the screen along with 0°.
This indicates correct distributor position.
If a plus (+) or a minus (-) is displayed next to the
degree number, and/or the degree displayed is not
zero, loosen but do not remove the distributor hold-
down clamp bolt. Rotate the distributor until I N
RANGE appears on the screen. Continue to rotate N U T
SHROUD J928J-2
the distributor until achieving as close to 0° as pos
sible. After adjustment, tighten clamp bolt to 22.5 Fig. 65 Shroud Removal/Installation—Typical
(4) Remove ignition switch mounting screws. Use KEY-IN SWITCH & MULTI-FUNCTION
tamper proof torx b i t Snap-on TTXR20A2 or equiva
lent to remove the screws (Fig. 66) or (Fig. 67).
Fig. 68 Key-ln-Switch and Halo Lamp Connector

(a) Insert key in ignition switch. Turn key to
LOCK position. Using a TTXR20A2 or equivalent
torx bit, remove key cylinder retaining screw and
bracket (Fig. 69) or (Fig. 70).
(b) Rotate key clockwise to the OFF position.
Key cylinder will unseat from ignition switch (Fig.
71). When key cylinder is unseated, it will be
approximately 1/8 inch away from ignition switch
Fig. 66 Ignition Switch Screw Removal halo light ring. Do not attempt to remove key
cylinder at this time.
(c) With key cylinder in unseated position, rotate
key counterclockwise to the lock position and
remove key.
SWITCH 958D-61
Fig. 67 Ignition Switch Screw Removal

(5) Gently pull switch away from column. Release
connector locks on 7-terminal wiring connector, then
remove connector from ignition switch.
(6) Release connector lock on 4-terminal connector,
then remove connector from ignition switch (Fig. 68). 958D-62
(7) To remove key cylinder from ignition switch:
Fig. 69 Key Cylinder Retaining Screw
(d) With key cylinder in unseated position,
rotate key counterclockwise to the lock position
and remove key
(e) Remove key cylinder from ignition switch
(Fig. 72).
BRACKET RETAINING
Fig. 72 Key Cylinder Removal

INSTALLATION
(1) Connect electrical connectors to ignition switch.
Make sure that switch locking tabs are fully seated
In wiring connectors.
(2) Before attaching ignition switch to a tilt steer
ing column, the transmission shifter must be In Park
position. The park lock dowel pin and column lock
flag must also be properly indexed before installing
958D-63
switch (Fig. 73).
Fig. 70 Key Cylinder Retaining Screw
\ KEY CYLINDER
908D-18
Fig. 73 Ignition Switch View From Column

(a) Place transmission shifter in PARK position.
(b) Place ignition switch in lock position. The
switch is in the lock position when column lock flag
is parallel to ignition switch terminals (Fig. 73).
(c) Position ignition switch park lock dowel pin
1
RING 908D-16 so it will engage steering column park lock slider
linkage (Fig. 74).
Fig. 71 Unseated Key Cylinder (d) Apply a light coating of grease to column lock
flag and park lock dowel pin.
8D - 30 IGNITION SYSTEM
HEH@WAL AHP INSTALLATION {Continued)

SPECIFICATIONS
LOCATING PIN HOLE K LOCK S L I D E R / X
^LINKAGE^-^^
VEC1 LABEL SPECIFICATIONS
I f anything differs between the specifications found
on the Vehicle Emission Control Information (VECI)
label and the following specifications, use specifica
tions on VECI label. The VECI label is located in the
engine compartment.
IGNITION TIMING
Ignition timing is not adjustable on any engine.
Refer to Ignition Timing in the Diagnostics/Service
Procedures section of this group for more informa
tion.
ENGINE FIRING ORDER—3.9L V-6 ENGINE

Fig. 74 ignition Switch Mounting Pad
(3) Place ignition switch against lock housing
opening on steering column. Ensure that ignition
switch park lock dowel pin enters slot in park lock
slider linkage in steering column.
(4) Install retaining bracket and ignition switch
mounting screws. Tighten screws to 3±.5 N-m (26±4
CLOCKWISE ROTATION
in. lbs.) torque. FRONT 1-6-5-4-3-2
(5) Install ignition lock cylinder: OF
(6) With lock cylinder and Ignition switch in Lock ENGINE
position, insert lock cylinder into ignition switch
until It bottoms.
(7) Insert ignition key into lock cylinder. While
gently pushing lock cylinder In toward ignition
switch, rotate ignition key to end of travel. J9314-80
(8) Install retaining screw into bracket and lock
cylinder. Tighten screw to 3±.5 N-m (26±4 in. lbs.)
ENGINE FIRING ORDER—5.2L/5.9L V-8 ENGINES
torque.
(9) Install steering column covers. Tighten screws
(10) I f vehicle is equipped with a tilt steering col
umn, install tilt lever.
(11) Connect negative cable to battery.
(12) Check for proper operation of halo light, shift
lock (if applicable), and column lock. Also check for
proper operation of ignition switch accessory, lock,
off, run, and start positions.
a
FRONT
CLOCKWISE ROTATION
1-8-4-3-6-5-7-2
OF
COLUMN SHIFT INTERLOCK ENGINE
The column shift interlock is used to lock the
transmission shifter in the Park position when the
key is in the Off position. The interlock device is
located within the steering column assembly and is J9314-79
not servicable. I f repair is necessary, the steering col
umn assembly must be replaced. Refer to Group 19,
Steering for procedures.
BR IGNITION SYSTEM 8 0 - 31
SPECIFICATIONS (Continued!
SPARK PLUG CABLE ORDER—8.0L V-10 ENGINE TORQUE SPECIFICATIONS
REAR COIL PACK FRONT COIL PACK DESCRIPTION TOEQUE
Camshaft Position
Sensor—8.0L Engine 6 N-m (50 in. lbs.)
Crankshaft Position
Sensor—All Engines 8 N-m (70 in. lbs.)
Distributor Hold Down Bolt . 23 N-m (17 ft. lbs.)
Ignition Coil Mounting—
3.9L/5.2L/5.9L Engines—
if tapped bolts are used . 5 N-m (50 in. lbs.)
3.9L/5.2L/5.9L Engines—
if nuts/bolts are used . 11 N-m (100 in. lbs.)
8.0L Engine . . . . . . . . . . . 10 N-m (90 in. lbs.)
Powertrain Control Module
(PCM) Mounting Screws 1 N-m (9 in. lbs.)
Spark Plugs (all engines) 41 N-m (30 ft. lbs.)
RIGHT LEFT
BANK BANK
FIRING ORDER
1-10-9-4.3.6-5-8-7-2 J 948D-12
SPA1I PLUGS
Spark Plug
lightening
Engine Original Application Gap Size
Replacement Torque
Equipment
14 nrr;
.035" 41 N.m
3.9L V-6 RC12YC RC12YC ALL Thread
(0.9MM) (30 ft. lbs.)
3/4" Reach
14 mm
.035" 41 N.m
5.2/5.9L V-8 RC12YC RC12YC ALL Thread
(0.9MM) (30 ft. lbs.)
3/4" Reach
14 mm
.045" 41 N.m
8.0L V-10 QC9MC4 QC9MC4 ALL Thread
(1.14MM) (30 ft. lbs.)
3/4" Reach
SPARK PLUG CABLE RESISTANCE
MINIMUM MAXIMUM
250 Ohms Per Inch 1000 Ohms Per Inch
3000 Ohms Per Foot 12,000 Ohms Per Foot
J908D-43
IGNITION COIL RESISTANCE—3.9L/5.2L/5.9L ENGINES
PRSMARY RESISTANCE S E C O N D A R Y RESISTANCE
COIL (MANUFACTURER) 21-27°C ( 7 0 - 8 0 ° F ) 21-27°C (70-80°F)
Diamond 0.97 - 1.18 Ohms 11,300- 15,300 Ohms
Toyodenso 0.95- 1.20 Ohms 11,300- 13,300 Ohms
JVS8D-2
IGNITION COIL RESISTANCE—8.0L ¥ 4 0 ENGINE
* Primary Resistance: 0.53 to 0.65 ohms

* * Secondary Resistance: 10.9 to 14.7 K ohms
* Test across the primary connector.

* * Test across the individual coil towers.

J948D-13
BR INSTRUMENT PANEL SYSTEMS 8E -1
INSTRUMENT PANEL SYSTEMS

CONTENTS
page page
GENERAL INFORMATION CLUSTER ILLUMINATION LAMPS 12

FUSEBLOCK MODULE 3 COOLANT TEMPERATURE GAUGE 8
GAUGES 3 FOUR-WHEEL DRIVE INDICATOR LAMP 12
INDICATOR LAMPS 3 FUEL GAUGE 8
INSTRUMENT C L U S T E R S 2 GENERATOR WARNING LAMP 13
INSTRUMENT PANEL 2 HEADLAMP HIGH BEAM INDICATOR LAMP . . 13
INTRODUCTION 2 LOW FUEL WARNING LAMP 13
MESSAGE CENTER 3 LOW OIL P R E S S U R E WARNING LAMP 14
DESCRIPTION AND OPERATION LOW WASHER FLUID WARNING LAMP 14
AIRBAG INDICATOR LAMP 4 MAINTENANCE REQUIRED INDICATOR LAMP . 15
ANTI-LOCK BRAKE SYSTEM LAMP 4 MALFUNCTION INDICATOR LAMP 15
BRAKE WARNING LAMP 5 OIL P R E S S U R E GAUGE 9
CLUSTER ILLUMINATION LAMPS 5 PRINTED CIRCUITS 7
COOLANT TEMPERATURE GAUGE 3 SEAT BELT REMINDER LAMP 16
FOUR-WHEEL DRIVE INDICATOR LAMP 5 SPEEDOMETER/ODOMETER 10
FUEL GAUGE 3 TACHOMETER 10
GEAR SELECTOR INDICATOR 4 TRANSMISSION OIL TEMPERATURE
GENERATOR WARNING LAMP 5 WARNING LAMP 16
HAZARD WARNING INDICATOR LAMP 5 TRIP ODOMETER 10
HEADLAMP HIGH BEAM INDICATOR LAMP .. . 5 TURN SIGNAL INDICATOR LAMPS 16
LOW FUEL WARNING LAMP 5 UPSHIFT INDICATOR LAMP 17
LOW OIL P R E S S U R E WARNING LAMP 6 VOLTMETER 10
LOW WASHER FLUID WARNING LAMP 6 WAIT-TO-START LAMP 17
MAINTENANCE REQUIRED INDICATOR LAMP . 6 WATER-IN-FUEL LAMP 17
MALFUNCTION INDICATOR LAMP 6 REMOVAL AND INSTALLATION
MASTER LIGHTING INDICATOR LAMP 6 ASH RECEIVER 18
OIL P R E S S U R E GAUGE 4 CIGAR LIGHTER/POWER OUTLET 19
SEAT BELT REMINDER LAMP 6 CLUSTER BEZEL 19
SPEEDOMETER/ODOMETER 4 CLUSTER BULBS 22
TACHOMETER 4 CLUSTER LENS AND MASK 20
TRANSMISSION OIL TEMPERATURE CUP HOLDER 18
WARNING LAMP 6 FUSEBLOCK MODULE 18
TRIP ODOMETER 4 GAUGES 20
TURN SIGNAL INDICATOR LAMPS 6 GEAR SELECTOR INDICATOR 22
UPSHIFT INDICATOR LAMP 6 GLOVE BOX LAMP/SWITCH/LATCH STRIKER . 25
VOLTMETER 4 GLOVE BOX LATCH 25
WAIT-TO-START LAMP 7 GLOVE BOX 24
WATER-IN-FUEL LAMP 7 HEADLAMP SWITCH 24
DIAGNOSIS AND TESTING INSIDE HOOD RELEASE 18
AIRBAG INDICATOR LAMP 11 INSTRUMENT CLUSTER 19
ANTI-LOCK BRAKE SYSTEM LAMP 11 INSTRUMENT PANEL ASSEMBLY 26
BRAKE WARNING LAMP 11 KNEE BLOCKER 18
8E - 2 INSTRUMENT PANEL SYSTEMS BR
LOW FUEL WARNING CIRCUIT 22 PRINTED CIRCUIT 22

MESSAGE CENTER BULBS 23 VEHICLE SPEED SENSOR 22
MESSAGE C E N T E R . . . . . . . . . . . . . . . . . . . . . . 23 SPECIFICATIONS
OIL PRESSURE SENDING UNIT . . . . . . . . . . . . 22- GAUGE CALIBRATION 29
OVERDRIVE LOCKOUT/FOG LAMP SWITCH . . 24
GENERAL I N F O R M A T I O N components can be accessed without complete instru

ment panel removal. I f necessary, the instrument
INTRODUCTION panel can be rolled-down and removed from the vehi
This group is responsible for covering the vehicle cle as an assembly.
instrument panel. However, because the instrument Removal of the instrument cluster bezel allows
panel serves as the vehicle's command center, i t is a access to the cluster assembly, most switches, the cli
very complex unit. The instrument panel is designed mate controls, and the radio. Removal of the cluster
to house the controls and monitors for standard and assembly allows access to the individual gauges, illu
optional powertrains, climate control systems, audio mination and indicator lamp bulbs, printed circuits,
systems, lighting systems, safety systems and many and most of the instrument panel wiring.
other comfort or convenience items. I t is also Removal of the steering column cover/knee blocker
designed so that all of the controls and monitors can provides access to the steering column mounts, the
be safely reached and/or viewed by the vehicle oper intermittent wipe module, the fuseblock module
ator, while still allowing relative ease of access to (removal of a snap-fit cover on the left end of the
these items for service. instrument panel allows access to the fuses and cir
Complete service information coverage for all of the cuit breakers) and the gear selector indicator cable
systems and components housed in the instrument (automatic transmission).
panel in this section of the service manual would not
be practical. I t would result in a great deal of dupli INSTRUMENT CLUSTERS
cation and make this group too large for the informa Two basic instrument cluster options are offered on
tion to be easily accessed and used. Therefore, the Ram truck models. One is referred to as a low-line
information found in this group has been limited as cluster, and the other is referred to as a high-line
follows: cluster. Each cluster is served by a printed circuit
• General Information - Covers non-electrical com and two wiring connectors. Some variations of each
ponents and features of the instrument panel that cluster exist due to optional equipment and regula
are not related to other systems. tory requirements.
• Description and Operation - Covers gauges and The low-line cluster includes the following gauges:
their sending units, warning lamps and their • Coolant temperature gauge
switches, and instrument panel illumination lamps. • Fuel gauge
• Diagnosis and Testing - Covers gauges and their • Gear selector indicator (automatic transmission)
sending units, warning lamps and their switches, • Oil pressure gauge
and instrument panel illumination lamps. • Speedometer/odometer.
• Removal and Installation - Covers components • Trip odometer
installed on or in the instrument panel that require • Voltmeter.
removal for diagnosis or service of instrument panel The low-line cluster includes provisions for the fol
components covered in this group. lowing indicator lamps:
For more information on components or systems • Airbag indicator lamp
not covered above, refer to the appropriate group in • Anti-lock brake system lamp
this manual. I f you are uncertain as to the appropri • Brake warning lamp
ate group, refer to the Component and System Index • Four-wheel drive indicator lamps
at the back of this manual. Refer to Group 8W - Wir • Generator warning lamp
ing Diagrams for complete circuit descriptions and • Headlamp high beam indicator lamp
diagrams. • Low oil pressure warning lamp
• Malfunction indicator (Check Engine) lamp
INSTRUMENT PANEL • Seat belt reminder lamp
Modular instrument panel construction allows all • Turn signal indicator lamps
of the gauges and controls to be serviced from the • Upshift indicator lamp.
front of the panel. In addition, most of the instru The high-line cluster includes all of the gauges and
ment panel wiring or heating and air conditioning indicator lamps found in the low line cluster, but
BR INSTRUMENT PANEL SYSTEMS 8E - 3
GENERAL INFORMATION ( C o n t i n u e d )
adds a analog tachometer, low fuel warning lamp and INDICATOR LAMPS
low washer fluid warning lamp. Some of the low line Indicator lamps are located in several areas of the
cluster gauges and indicator lamps have different instrument cluster and the instrument panel. Those
positions, or sizes in the high line cluster to accommo lamps within the gauge area of the cluster are served
date the tachometer. by the cluster printed circuit(s) and cluster connec
tors). Those lamps located in the message center
MESSAGE CENTER area of the cluster are served by the message center
In addition to the warning lamps found in the printed circuit and connector.
instrument cluster, a message center located directly
below the climate controls has provisions for up to FUSEBLOCI MODULE
five warning lamps. These lamps may or may not be The fuseblock module is mounted to the left end of
functional, depending upon the optional equipment the instrument panel. I t has cavities for 24 blade-
and regulatory' requirements affecting the vehicle type fuses and circuit breakers, the turn signal and
being serviced. The available lamps in the message hazard warning flashers, a buzzer module, and the
center include: ignition switch lamp time delay relay.
• Hazard warning indicator (export vehicles) The fuses, circuit breakers, flashers, and relay can
® Maintenance required indicator (heavy-duty be accessed by removing a snap-in cover located on
emissions cycle engines) the left outboard end of the instrument panel. The
@ Master lighting Indicator (export vehicles) fuseblock module can be accessed for removal from
• Transmission oil temperature warning (V-10 and under the instrument panel by removing the lower
diesel engines with an automatic transmission) steering column cover/knee blocker.
® Wait-to-start (diesel engines)
• Water-In-fuel (diesel engines).
DESCRIPTION AN© OPERATION
GAUGES
With the ignition switch i n the On or Start posi COOLANT TEMPERATURE GAUGE
tions, voltage Is supplied to all gauges through the . The coolant temperature gauge gives an indication
Instrument cluster printed circuits. With the Ignition of the engine coolant temperature. The coolant tem
switch in the Off position, voltage is not supplied to perature sending unit is a thermistor that changes
the gauges. A gauge pointer may remain within the electrical resistance with changes in the engine cool
gauge scale with the ignition switch In the Off posi ant temperature. Some gauge needle cycling, depend
tion. However, the gauges do not accurately indicate ing upon the vehicle load, is normal on models
any vehicle condition unless the ignition switch is in equipped with the diesel engine option. High sending
the On or Start positions. unit resistance causes low coolant temperature read
All gauges, except the odometer, are air core mag ings. Low resistance causes high coolant temperature
netic units. Two fixed electromagnetic coils are readings. The sending unit resistance values are
located within the gauge. These coils are wrapped at shown in a chart in Specifications at the back of this
right angles to each other around a movable perma group.
nent magnet. The movable magnet is suspended
within the coils on one end of a shaft. The gauge nee FUEL GAUGE
dle Is attached to the other end of the .shaft. The fuel gauge gives an indication of the level of
One of the coils has a fixed current flowing fuel in the fuel tank. The fuel gauge sending unit is
through it to maintain a constant magnetic field mounted to^the electric fuel pump module located
strength. Current flow through the second coil inside the fuel tank. Refer to Group 14 - Fuel System
changes, which causes changes in its magnetic field for sending unit service procedures.
strength. The current flowing through the second coil The sending unit has a float attached to the end of
can be changed by: a swing-arm. The float moves up or down within the
• A variable resistor-type sending unit (fuel level, fuel tank as the fuel level changes. As the float
coolant temperature, or oil pressure gauges) moves, an electrical contact on the pivot end of the
• Changes In electrical system voltage (voltmeter) swing-arm wipes across a resistor coil, which changes
• Electronic control circuitry (speedometer/odome the resistance of the sending unit. High sending unit
ter, tachometer). resistance causes low fuel level readings; Low resis
The gauge needle moves as the movable permanent tance causes high fuel level readings. The sending
magnet aligns itself to the changing magnetic fields unit resistance values are shown i n a chart in Spec
created around It by the electromagnets. ifications at the back of this group.
GEAR SELECTOR INDICATOR the tachometer unit reads and analyzes this pulse
The gear selector indicator gives an indication of signal. I t then adjusts the ground path resistance for
the position of the automatic transmission gear selec one of the electromagnets in the gauge to control
tor lever. The indicator is mounted to the instrument gauge needle movement. The frequency values for
cluster housing. the pulse signal are shown in a chart in Specifica
The indicator is mechanically actuated by a cable tions at the back of this group.
connected to the PRNDL driver of the gear selector
lever mechanism on the steering column. This group TRIP ODOMETER
covers only the removal and Installation of the gear Like the odometer, the trip odometer gives an indi
selector indicator. Refer to Group 21 - Transmission cation of the distance the vehicle has travelled. How
for the diagnosis and adjustment of this component. ever, by depressing the trip odometer reset knob on
the face of the speedometer/odometer unit, the trip
OIL PRESSURE GAUGE odometer number rolls can be reset to zero. The trip
The oil pressure gauge gives an indication of the odometer is driven by the same signal and circuits as
engine oil pressure. The combination oil pressure the speedometer and odometer. The trip odometer is
switch/sending unit contains a flexible diaphragm serviced only as a part of the speedometer/odometer
and a variable resistor coil. The diaphragm moves in gauge unit.
response to changes in the engine oil pressure. The
sending unit is installed in a threaded hole that pen VOLTMETER
etrates a oil passage of the engine. As the diaphragm The voltmeter gives an indication of the vehicle's
moves, resistance in the coil increases or decreases. electrical system voltage. The voltmeter is connected
High resistance on the gauge side of the sending unit in parallel with the battery. With the ignition switch
causes low oil pressure readings. Low resistance in the On position, the voltmeter indicates the bat
causes high oil pressure readings. Sending unit resis tery voltage or the generator output voltage, which
tance values are shown in a chart in Specifications at ever is greater.
the back of this group.
AIRBAG INDICATOR L A i P
SPEEDOMETER/ODOMETER The airbag indicator lamp lights for 6 to 8 seconds
The speedometer/odometer gives an indication of each time the ignition switch is turned to the On
the current vehicle speed, and displays a cumulative position as a bulb test, and to indicate that a system
total of the distance the vehicle has traveled. The self-test is in progress. The lamp is switched to
speedometer/odometer unit receives a vehicle speed ground by the Airbag Control Module (ACM). I f the
pulse signal from the Vehicle Speed Sensor (VSS). An lamp remains on after the self-test, or comes on
electronic integrated circuit contained within the while driving, i t may indicate that the ACM has
speedometer/odometer unit reads and analyzes the detected a system malfunction and/or that the airbag
pulse signal. I t then adjusts the ground path resis system has become inoperative. Refer to Group 8 M -
tance of one electromagnet in the gauge to control Passive Restraint Systems for more information.
speedometer needle movement. I t also sends signals
to an electric stepper motor to control movement of ANTI-LOCK BRAKE SYSTEM LAMP
the odometer number rolls. The frequency values for
the pulse signal are shown in a chart in Specifica R E A R WHEEL ANTI-LOCK
tions at the back of this group. On vehicles equipped with the standard Rear
The VSS is mounted to an adapter near the trans Wheel Anti-Lock (RWAL) brake system, the Anti-
mission (two-wheel drive) or transfer case (four-wheel Lock Brake System (ABS) lamp is switched to ground
drive) output shaft. The sensor is driven through the by the RWAL control module. The RWAL control
adapter by a speedometer pinion gear. The adapter module lights the lamp when the ignition switch is
and pinion used may vary with transmission and turned to the Start position as a bulb test. The lamp
transfer case models, axle ratio and tire size. Refer to will stay on for 3 to 5 seconds after vehicle start-up
Group 21 - Transmission for more information. to indicate that a system self-test is in progress. I f
the lamp remains on after start-up, or comes on and
TACHOMETER stays on while driving, it may indicate that the
The tachometer gives an indication of the engine RWAL control module has detected a system mal
speed in revolutions-per-minute (rpm). With the function and/or that the RWAL system has become
engine running, the tachometer receives an engine inoperative. Refer to Group 5 - Brakes for more infor
speed pulse signal from the powertrain control mod mation.
ule. An electronic integrated circuit contained within
D E S C R I P T I O N UNO OPERATION fContinued)
ANTI-LOOK BRAKE SYSTEM four-wheel drive switch is threaded into the front
The optional all-wheel Anti-Lock Brake System axle disconnect housing. The switch is connected in
(ABS) lamp is grounded through the normally closed series between the other side of the indicator lamp
contacts of the de-energized ABS lamp relay. When bulb and ground. When the vacuum-actuated front
the ignition switch is turned to the Start position, axle disconnect is engaged, providing four-wheel
the lamp is lighted as a bulb test. The lamp will stay drive, the plunger of the four-wheel drive switch is
on for 3 to 5 seconds after vehicle start-up to indicate moved by the internal axle disconnect mechanism,
a system self-test is in progress. I f the self-test is closing the switch and providing a path to ground.
successfully completed, the Controller Anti-lock This causes the four-wheel drive indicator lamp bulb
Brake (CAB) module energizes the ABS lamp relay, to light.
which turns the lamp off. I f the lamp remains on
after start-up, or comes on and stays on while driv GENERATOR WARNING LAMP
ing, i t may indicate that the CAB module has The generator warning lamp gives the driver an
detected a system malfunction and/or that the ABS indication of a charging system problem. One side of
system has become inoperative. Refer to Group 5 - the bulb is connected to an ignition-switched battery
Brakes for more information. feed. The other side of the bulb is switched to ground
by the Powertrain Control Module (PCM).
BRAKE WARNING LAMP The lamp should light when the ignition switch is
The brake warning lamp gives the driver an indi turned to the On position, but should go out when
cation that the parking brake is applied, or that the ever the engine is running. I f the lamp comes on and
pressures in the two halves of the split brake stays on while the engine is running, i t indicates
hydraulic system are unequal. With the ignition that the PCM has detected a charging system mal
switch turned to the On or Start positions, battery function and/or that the charging system has become
voltage is supplied to one side of the indicator bulb. A inoperative.
ground path for the bulb is provided by up to five Refer to Group 8C - Charging System for diagnosis
switches. The bulb will light when: of a charging system problem. Refer to Group 14 -
• The ignition switch is in the Start position (bulb Fuel System for more information on the PCM gen
test). erator warning lamp control output.
• The brake warning switch is closed (indicating
unequal split brake hydraulic system pressures, due HAZARD WARNING INDICATOR LAMP
to low brake fluid or brake fluid leakage). The hazard warning indicator lamp is only used on
• The parking brake switch is closed (indicating certain export models, where required. The lamp in
the parking brake is applied). the message center is turned on by a signal from the
• The vacuum sensor (models with the diesel hazard warning (multi-function) switch to indicate
engine option) senses low system vacuum. that the hazard warning lamp system is activated.
• I f certain ABS or RWAL system faults are
detected. HEADLAMP HIGH BEAM INDICATOR LAMP
Refer to Group 5 - Brakes for more information. The headlamp high beam indicator lamp lights
when the high beam circuit is activated. The circuit
CLUSTER ILLUMINATION LAMPS is controlled by the headlamp dimmer (multi-func
Each of the instrument cluster illumination lamps tion) switch. One side of the indicator bulb is
receives battery feed through the panel dimmer rheo grounded at all times. The other side of the bulb
stat of the headlamp switch from the instrument receives a battery feed through the contacts of the
lamps fuse in the fuseblock module. When the park dimmer switch when the multi-function switch stalk
or head lamps are on, the cluster illumination lamps is actuated to turn on the headlamp high beams.
light. Illumination brightness can be adjusted by Refer to Group 8L - Lamps for more information.
rotating the headlamp switch knob (clockwise to dim,
counterclockwise to brighten). LOW FUEL WARNING LAMP
The low fuel warning lamp will light when the fuel
FOUR-WHEEL DRIVE INDICATOR LAMP level falls below approximately four gallons. One side
1
On models equipped with the four-wheel drive of the low fuel warning bulb is grounded at all times.
option, a four-wheel drive indicator lamp in the A low fuel warning circuit attached to the rear of the
instrument cluster lights any time the front axle is in gauge cluster provides ignition-switched battery volt
the four-wheel drive operating mode. Ignition- age to the lamp when the fuel level is low. The low
switched battery voltage is supplied to one side of the fuel warning circuit monitors the signal from the fuel
indicator lamp bulb. A normally open, plunger-type, level sending unit. When the circuit senses approxi-
mately 65 ohms or more from the fuel level sending a bulb test. I f the Powertrain Control Module (PCM)
unit for 8 to 30 continuous seconds, the indicator receives an incorrect signal or no signal from certain
lamp will light. The indicator lamp will remain on fuel or emission system related circuits or compo
until the circuit senses approximately 65 ohms or nents, the lamp is turned on. This indicates that the
less from the fuel sender for 8 to 30 continuous sec PCM has recorded a Diagnostic Trouble Code (DTC)
onds. See the chart i n Specifications at the back of in electronic memory for a circuit or component mal
this group for more information. function. Refer to Group 14 - Fuel System for more
information.
LOW OIL PRESSURE WARNING LAMP
The low oil pressure warning lamp lights with the MASTER LIGHTING INDICATOR LMIVIP
ignition switch in the On position and the engine not The master lighting indicator lamp is only used on
running. The lamp should be off when the engine is certain export models, where required. The lamp in
running. the message center is turned on by a signal from the
Battery voltage is supplied to one side of the indi headlamp switch to indicate that the exterior lamps
cator bulb when the ignition switch is turned to the are lighted. .
On position. The warning lamp side of the combina
tion oil pressure switch/sending unit resistor coil is SEAT BELT REMINDER LAMP
connected to the other side of the bulb. The seat belt reminder lamp lights for four to eight
When normal engine oil pressure is applied to the seconds after the ignition switch is turned to the On
sending unit, resistance on the warning lamp side of position. A timer circuit within the chime/buzzer
the resistor coil is high and the lamp goes off. When module controls ignition-switched battery feed to the
the engine oil pressure is too low, resistance on the lamp. Refer to Group 8U - Chime/Buzzer Warning
warning lamp side of the resistor coil is low, which Systems for more information.
causes the bulb to light.
TRANSMISSION OIL TEMPERATURE WARNING
LOW WASHER FLUID WARNING LAMP LAMP
The low washer fluid warning lamp indicates when The transmission oil temperature warning lamp
the fluid level in the washer fluid reservoir is too low. lights to indicate that the transmission oil is over
The washer fluid level sensor uses a float in the res heated. One side of the lamp bulb receives battery
ervoir to monitor the fluid level. The up and/or down voltage when the ignition switch is turned to the On
action of the float opens or closes the switch within position. The other side of the bulb is grounded by
the sensor that provides a ground path to the warn the Powertrain Control Module (PCM), when i t
ing lamp bulb. Refer to Group 8K - Wiper and senses transmission oil temperature is too high. A
Washer Systems for more information. sensor located within the transmission sends a signal
to the PCM, indicating the transmission fluid tem
MAINTENANCE REQUIRED INDICATOR LAMP perature. Refer to Group 21 - Transmission for more
The maintenance required indicator lamp is used information on the sensor and its circuit. This lamp
on vehicles equipped with a heavy-duty emissions is only used on vehicles equipped with a diesel or
cycle package, and a 5.9L V-8, or 8.0L V-10 engine. V-10 engine option, and an automatic transmission.
This lamp is intended to act as a reminder that
scheduled vehicle emissions services and mainte TURN SIGNAL INDICATOR LAMPS
nance must be performed, as required by federal The left and right turn signal indicator lamps are
emissions laws. I t is not intended to indicate a warn controlled by the turn signal and hazard warning
ing, or that a state of emergency exists. However, (multi-function) switches. One side of the bulb for
when the lamp has been activated, the required ser each lamp is grounded at all times. The other side of
vices and maintenance must be performed, before the the bulb receives a battery feed through the contacts
lamp can be legally reset. For a list of the required of the multi-function switch when the turn signal
services and maintenance, stated in time or mileage, lever (multi-function switch stalk) or hazard warning
refer to Group 0 - Lubrication and Maintenance. Also button is actuated. Refer to Group 8J - Turn Signal
refer to Group 25 - Emission Control System for and Hazard Warning Systems for more information.
more information.
UPSHIFT INDICATOR LAMP
MALFUNCTION INDICATOR LAMP Vehicles equipped with a manual transmission may
The Check Engine or Malfunction Indicator Lamp have an optional upshift indicator lamp. One side of
(MIL) lights each time the ignition switch is turned the indicator lamp bulb receives ignition-switched
to the On position, and stays on for three seconds as battery feed. The ground feed for the other side of

the lamp bulb is switched by the Powertrain Control gauge or lamp. For circuit descriptions and diagrams,
Module (PCM). The lamp lights to indicate when the refer to 8W-40 - Instrument Cluster in Group 8W -
driver should shift to the next highest gear for best Wiring Diagrams. I f more than one gauge or lamp is
fuel economy. The PCM will turn the lamp off after 3 inoperative, perform the following:
to 5 seconds if the upshift is not performed. The lamp (1) Check the fuse in the fuseblock module. I f OK,
will remain off until the vehicle stops accelerating go to Step 2. I f not OK, replace the faulty fuse.
and Is brought back to the range of lamp operation, (2) Check for battery voltage at the fuse with the
or until the transmission is shifted into another gear. ignition switch in the On position. I f OK, go to Step
The indicator lamp is normally on when the Igni 3. I f not OK, repair the open circuit from the ignition
tion switch is in the On position, and is turned off switch and/or refer to Group 8D - Ignition Systems
when the engine is started. The lamp will be turned for testing of the ignition switch, as required.
on and off during vehicle operation, according to the (3) Turn the ignition switch to the Off position.
engine speed and load conditions that are being mon Disconnect and isolate the battery negative cable.
itored by the PCM. Refer to Group 14 - Fuel System Remove the instrument cluster bezel and the cluster
for more Information on the PCM upshift indicator assembly. Disconnect the gauge cluster connectors.
lamp control output. (4) Connect the battery negative cable. Turn the
ignition switch to the On position. Check for battery
WAIT-TO-START LAMP voltage at the fused ignition switch output circuit
The wait-to-start lamp Is only used on diesel cavity of the right cluster connector. I f OK, go to Step
engine models. The wait-to-start lamp bulb In the 5. I f not OK, repair the open circuit from the fuse as
message center is lighted by a ground signal from the required.
Powertrain Control Module (PCM), after the ignition (5) Turn the ignition switch to the Off position.
switch is turned to the On position. It gives the Disconnect and isolate the battery negative cable.
driver an indication to wait until the intake manifold Probe the ground circuit cavities of both the left and
air heater grid has had sufficient time to warm the right cluster connectors. Check for continuity to a
intake air for a good quality start. The intake mani good ground. There should be continuity. I f OK,
fold air preheat cycle is controlled by an electronic replace the faulty gauge cluster printed circuit. I f not
air heater control module. The lamp will be turned OK, repair the open circuit(s) to ground as required.
off by the PCM when the heater control module cycle
is completed, or i f the driver turns the Ignition MESSAGE CENTER
switch to the Start position prior to the end of the If an individual lamp is inoperative, see the diag
heater control module cycle. Refer to Group 14 - Fuel nostic procedure under the heading for that lamp.
Systems for more information. The message center printed circuit is only serviced as
a part of the heater-A/C control unit. I f the printed
WATER-IN-FUEL LAMP circuit is faulty, the entire control unit must be
The water-in-fuel lamp is only used on models with replaced. For circuit descriptions and diagrams, refer
the diesel engine option. The water-in-fuel lamp i n to 8W-46 - Message Center in Group 8W - Wiring
the message center is turned on by the Powertrain Diagrams. I f more than one lamp is inoperative, per
Control Module (PCM) for two seconds, when the form the following:
Ignition switch is first turned to the On position, as a (1) Check the fuse in the fuseblock module. I f OK,
bulb check. The PCM will also turn on the lamp any go to Step 2. I f not OK, replace the faulty fuse.
time there is excess water accumulated in the fuel (2) Check for battery voltage at the fuse with the
filter/water separator and the ignition switch Is In ignition switch in the On position. I f OK, go to Step
the On position. A water-in-fuel sensor In the fuel fil 3. I f not OK, repair the open circuit from the ignition
ter/water separator signals the PCM' that excess switch and/or refer to Group 8D - Ignition Systems
water has accumulated. The PCM will turn the lamp for testing of the ignition switch, as required.
off when the excess water has been' drained. Refer to (3) Turn the ignition switch to the Off position.
Group 14 - Fuel Systems for more information. Disconnect and isolate the battery negative cable.
Remove the instrument cluster bezel and the mes
sage center assembly. Disconnect the message center
DIAGNOSIS AND TESTING connector.
(4) Connect the battery negative cable. Turn the
PRINTED CIRCUITS ignition switch to the On position. Check for battery
voltage at the fused ignition switch output circuit
GAUGE CLUSTER cavity of the message center connector. I f OK, replace
If an Individual gauge or lamp is Inoperative, see the faulty heater-A/C control unit. I f not OK, repair
the diagnostic procedure under the heading for that the open circuit from the fuse as required.
COOLANT TEMPERATURE GAUGE

The diagnosis found here addresses an inoperative
gauge condition. I f the problem being diagnosed is
related to gauge accuracy, be certain to confirm that
the problem is with the gauge and not with cooling
system performance. The actual engine coolant tem
perature should be checked with a test gauge or ther
mometer and compared to the gauge readings before
you proceed with gauge diagnosis. Refer to Group 7 -
Cooling System for more information. For circuit
descriptions and diagrams, refer to 8W-40 - Instru
ment Cluster in Group 8W - Wiring Diagrams.
NOTE: Models equipped with the 8.0L V-10 engine

have the coolant temperature sending unit threaded
into the plastic water outlet. Therefore, an extra
spade terminal and connector near the side of the Fig. 2 Coolant Temperature Sending Unit - V-10
coolant temperature sending unit is wired to pro Engine '
vide a ground path for the sending unit case. Be
certain that there is continuity between the sending
unit case and ground on these models. If not OK,
repair this circuit to ground as required.
(1) Turn the ignition switch to the On position.

Disconnect the coolant temperature sending unit con
nector (Fig. 1), (Fig. 2) or (Fig. 3). The gauge needle
should move to the low end of the gauge scale. I f OK,
go to Step 2. I f not OK, go to Step 3.
Fig. 3 Coolant Temperature Sending Unit - Diesel

Engine
(4) Probe the engine coolant temperature sending
unit circuit cavity of the left cluster connector. Check
for continuity to a good ground. There should be no
continuity. I f OK, go to Step 5. I f not OK, repair the
short circuit as required.
(5) Still probing the engine coolant temperature
sending unit circuit cavity of the left cluster connec
tor, check for continuity to the sending unit connec
Fig. 1 Cooiant Temperature Sending Unit - V-6/V-8
tor. There should be continuity. I f OK, replace the
Engine
faulty gauge. I f not OK, repair the open circuit as
(2) Install a jumper wire from the sending unit required.
connector to a good ground. The gauge needle should
move to the high end of the gauge scale. I f OK, FUEL GAUGE
replace the faulty sending unit. I f not OK, remove The diagnosis found here addresses an inoperative
the jumper wire and go to Step 3. gauge condition. I f the problem being diagnosed is
(3) Turn the ignition switch to the Off position. related to gauge accuracy, be certain to confirm that
Disconnect and isolate the battery negative cable. the problem is with the gauge or sending unit and
Remove the instrument cluster bezel and the cluster not with the fuel tank. Inspect the fuel tank for signs
assembly. Disconnect the left cluster connector. of damage or distortion that could affect the sending
unit performance before you proceed with gauge

diagnosis. Refer to Group 14 - Fuel System for more EGR VALVE
information. For circuit descriptions and diagrams,
refer to 8W-40 - Instrument Cluster in Group 8W -
Wiring Diagrams.
(1) Turn the Ignition switch to the On position.
Disconnect the fuel pump module connector. The con
nector is located on top of the fuel tank. The gauge
needle should move to the low end of the gauge scale.
I f OK, go to Step 2. I f not OK, go to Step 4.
(2) Connect a jumper wire between the sending
unit ground circuit cavity and the fuel level sensor
signal circuit cavity of the fuel pump module wiring
connector. The gauge needle should move to the high
end of the gauge scale. I f OK, refer to Group 14 - OIL PRESSURE -
Fuel System for the procedures to replace the faulty SENDING UNIT J938E-35
sending unit. I f not OK, remove the jumper wire and
go to Step 3.
Fig. 4 Oil Pressure Switch/Sending Unit - V-6/V-8
Engine
Disconnect and isolate the battery negative cable.
Check for continuity between the sending unit
ground circuit cavity of the fuel pump module wiring
connector and a good ground. There should be conti
nuity. I f OK, go to Step 4. I f not OK, repair the open
circuit to ground as required.
(4) Remove the instrument cluster bezel and the
cluster assembly. Disconnect the right cluster connec
tor.
(5) Probe the fuel level sensor signal circuit cavity
of the right cluster connector. Check for continuity to
a good ground. There should be no continuity. I f OK,
go to Step 6. I f not OK, repair the short circuit as
required.
(6) Check for continuity between the fuel level sen
sor signal circuit cavities of the right cluster connec
tor and the. fuel pump module connector. There
should be continuity. I f OK, replace the faulty gauge.
If not OK, repair the open circuit as required.
OIL PRESSURE OAUIE

The diagnosis found here addresses an inoperative J948E-38
gauge condition. I f the problem being diagnosed is
related to gauge accuracy, be certain to confirm that Fig. 5 Oil Pressure Switch/Sending Unit • V-10
the problem is with the gauge and not with the Engine
engine oiling system performance. The actual engine (2) Install a jumper wire from the oil pressure sen
oil pressure should be checked with a test gauge and sor signal circuit cavity of the sending unit connector
compared to the Instrument cluster gauge readings to a good ground. The gauge needle should move to
before you proceed with gauge diagnosis. Refer to the high end of the gauge scale. I f OK, replace the
Group 9 - Engines for more information. For circuit faulty sending unit. I f not OK, remove the jumper
descriptions and diagrams, refer to 8W-40 - Instru wire and go to Step 3.
ment Cluster in Group 8W - Wiring Diagrams.
(1) Turn the ignition switch to the On position. Disconnect and isolate the battery negative cable.
Disconnect the oil pressure sending unit connector Remove the instrument cluster bezel and the cluster
(Fig. 4), (Fig. 5) or (Fig. 6). The gauge needle should assembly. Disconnect the right instrument cluster
move to the low end of the gauge scale. I f OK, go to connector.
Step 2. I f not OK, go to Step 3. (4) Probe the oil pressure sensor signal circuit cav
ity of the right cluster connector and check for conti-
8E - 1 0 INSTRUMENT PANEL SYSTEMS BR
(4) Check for continuity between the vehicle speed
sensor signal circuit cavities of the left cluster con
nector and the vehicle speed sensor connector. There
should be continuity. I f OK, replace the faulty speed
ometer/odometer unit. I f not OK, repair the open cir
cuit as required.
TACHOMETER
8W-40 - Instrument Cluster in Group 8W - Wiring
Diagrams.
(1) With the engine running, check for a tachome
ter signal at the tachometer signal circuit cavity of
the PCM connector C (gray). See the Tachometer Cal
ibration chart in Specifications at the back of this
group for the frequency ranges. I f OK, go to Step 2. I f
not OK, refer to the appropriate Powertrain Diagnos
tic Procedures manual to test the PCM.
PUMP ENGINE BLOCK
cable. Unplug the PCM connector C. Remove the
instrument cluster bezel and the cluster assembly.
Fig. 6 Oil Pressure Switch/Sending Unit - Diesei Disconnect the right instrument cluster connector.
Engine (3) Probe the tachometer signal circuit cavity of
nuity to a good ground. There should be no the right cluster connector. Check for continuity to a
continuity. I f OK, go to Step 5. I f not OK, repair the good ground. There should be no continuity. I f OK, go
short circuit as required. to Step 4. I f not OK, repair the short circuit as
(5) Check for continuity between the oil pressure required.
sensor signal circuit cavities of the right cluster con (4) Check for continuity' between the tachometer
nector and the sending unit connector. There should signal circuit cavities of the right cluster connector
be continuity. I f OK, replace the faulty gauge. I f not and the PCM connector C. There should be continu
OK, repair the open circuit as required. ity. I f OK, replace the faulty tachometer. I f not OK,
repair the open circuit as required.
SPEEDOMETER/ODOMETER
The diagnosis found here addresses an Inoperative TRIP ODOMETER
gauge condition. I f the problem being diagnosed is If the trip odometer is inoperative, but the speed
related to gauge accuracy, be certain to confirm that ometer/odometer functions are unaffected, replace the
the problem is with the gauge and not with an incor faulty speedometer/odometer unit. I f the speedome
rect speedometer pinion, axle ratio, or tire size. Refer ter/odometer functions are affected, see the diagnosis
to Group 21 - Transmission for more information. For for Speedometer/Odometer i n this group.
circuit descriptions and diagrams, refer to 8W-40 -
Instrument Cluster in Group 8W - Wiring Diagrams. VOLTMETER
(1) Perform the vehicle speed sensor test as The diagnosis found here addresses an inoperative
described in the appropriate Powertrain Diagnostic gauge condition. I f the gauge accuracy is suspect, be
Procedures manual. I f OK, go to Step 2. I f not OK, certain to confirm proper charging system operation
replace the faulty vehicle speed sensor. before considering gauge replacement.. Refer to Group
(2) Disconnect and isolate the battery negative 80 - Charging System for more information. I f no
cable. Unplug the vehicle speed sensor connector, the charging system problem is found, the following pro
buzzer module connector (export only), and the PCM cedure will help diagnose an inaccurate gauge. For
connector B (white). Remove the instrument cluster circuit descriptions and diagrams, refer to 8W-40 -
bezel and the cluster assembly. Disconnect the left Instrument Cluster i n Group 8W - Wiring Diagrams.
instrument cluster connector. (1) Turn the ignition switch to the On position.
(3) Probe the vehicle speed sensor signal circuit The voltmeter should read battery voltage. I f all
cavity of the left cluster connector. Check for continu gauges except the voltmeter are OK, go to Step 2. I f
ity to a good ground. There should be no continuity. the other gauges are inoperative, see the diagnosis
If OK, go to Step 4. I f not OK, repair the short circuit for Printed Circuits in this group.
as required.
BR INSTRUMENT PANEL SYSTEMS 8E -11
DIAGNOSIS A N D TESTING (Continued)

(2) Using an accurate test voltmeter, measure the output circuit and the ABS warning lamp driver cir
battery voltage at the battery Compare this reading cuit cavities of the right cluster connector within five
to the instrument cluster voltmeter reading. Now, see seconds of turning the ignition switch to the On posi
the Voltmeter Calibration chart in Specifications at tion. I f OK, replace the faulty bulb. I f not OK, go to
the back of this group. I f the voltmeter does not per Step 3.
form within the specifications, replace the faulty volt (3) Disconnect and isolate the battery negative
meter. cable. Disconnect the RWAL/ABS control module con
nector. I f the vehicle has ABS, remove the ABS lamp
AIRBAG INDICATOR LAMP relay from the Power Distribution Center (PDC). See
The diagnosis found here addresses an inoperative the PDC label for relay identification and location.
lamp condition. I f the airbag indicator lamp stays on Check for continuity between the ABS warning lamp
with the ignition switch in the On position, or comes driver circuit cavity of the right cluster connector and
on while driving, refer to Group 8M - Passive a good ground. There should be no continuity. I f OK,
Restraint Systems for diagnosis. I f no airbag system go to Step 4. I f not OK, repair the short circuit as
problem is found, the following procedure will help required.
locate a short or open in the airbag warning lamp (4) Check for continuity between the ABS warning
circuit. For circuit descriptions and diagrams, refer to lamp driver circuit cavities of the right cluster con
8W-40 - Instrument Cluster, and 8W-43 - Airbag Sys nector and the RWAL/ABS control module connector.
tem in Group 8W - Wiring Diagrams. There should be continuity. I f OK, refer to Group 5 -
(1) Disconnect and isolate the battery negative Brakes for diagnosis of RWAL/ABS control module. I f
cable. Remove the instrument cluster bezel and the not OK, repair the open circuit as required.
cluster assembly. Unplug the left instrument cluster
connector. BRAKE WARNING LAMP
(2) Connect the battery negative cable. Check for The diagnosis found here addresses an inoperative
battery voltage at the airbag system warning lamp brake warning lamp condition. I f the brake warning
driver circuit cavity of the left cluster connector lamp stays on with the ignition switch in the On
within 6 seconds after turning the ignition switch to position and the parking brake released, refer to
the On position. I f OK, replace the faulty bulb. I f not Group 5 - Brakes for diagnosis. I f no service brake or
OK, go to Step 3. parking brake problem is found, the following proce
(3) Turn the ignition switch to the Off position. dure will help locate a short circuit or a faulty
Disconnect and isolate the battery negative cable. switch. For circuit descriptions or diagrams, refer to
Disconnect the 13-way Airbag Control Module (ACM) 8W-40 - Instrument Cluster, and 8W-34 - Rear Wheel
connector. Check for continuity between the airbag Anti-Lock Brakes, or 8W-35 - All-Wheel Anti-Lock
system warning lamp driver circuit cavities of the Brakes in Group 8W - Wiring Diagrams.
left cluster connector and the ACM connector. There (1) Turn the ignition switch to the Start position.
should be continuity. I f OK, refer to Group 8M - The lamp should light. Release the ignition switch to
Restraint Systems for diagnosis of the ACM. I f not the On position. The lamp should go off. I f not OK,
OK, repair the open circuit as required. go to Step 2.
ANTI-LOCK BRAKE SYSTEM LAMP Unplug the brake warning switch connector. Check
The diagnosis found here addresses an inoperative for continuity between the switch terminal and a
Anti-lock Brake System (ABS) lamp condition. I f the good ground. There should be no continuity. I f OK, go
ABS lamp stays on with the ignition switch in the to Step 3. I f not OK, replace the faulty brake warn
On position, or comes on and stays on while driving, ing switch.
refer to Group 5 - Brakes for diagnosis. I f no RWAL (3) Unplug the parking brake switch connector.
or ABS problem is found, the following procedure will With the parking brake released, check for continuity
help locate a short or open i n the ABS lamp circuit. between the switch terminal and a good ground.
For circuit descriptions and diagrams, refer to 8W-40 There should be no continuity. Apply the parking
- Instrument Cluster, and 8W-34 - Rear Wheel Anti- brake and check for continuity between the switch
Lock Brakes or 8W-35 - All-Wheel Anti-Lock Brakes terminal and a good ground. There should be conti
in Group 8W - Wiring Diagrams. nuity. I f OK, go to. I f not OK, adjust or replace the
(1) Disconnect and isolate the battery negative parking brake switch as required.
cable. Remove the instrument cluster bezel and the (4) Check for continuity between the metal steer
cluster assembly. ing column jacket and a good ground. There should
(2) Connect the battery negative cable. Check for be continuity. I f OK, go to Step 5. I f not OK, refer to
battery voltage between the fused ignition switch
8E - 1 2 INSTRUMENT PANEL SYSTEMS BR
PI A6NGSIS AMD TESTING (Continued!

Group 19 - Steering to check the steering column module. Rotate the headlamp switch knob clockwise
ground clip Installation. while observing the test voltmeter. The reading
(5) Disconnect and isolate the battery negative should go from battery voltage to zero volts. I f OK,
cable. Unplug the ignition switch connector. While go to Step 3. I f not OK, repair the open circuit to the
holding the ignition switch in the Start position, headlamp switch or refer to Group 8L, - Lamps to
check for continuity between the red brake warning diagnose the headlamp switch.
lamp driver circuit terminal of the ignition switch (3) . Disconnect and Isolate the battery negative
and a good ground. There should be continuity. cable. Remove the instrument cluster bezel and the
Release the ignition switch to the On position and cluster assembly. Unplug the right cluster connector.
check for continuity again. There should be no conti Connect the battery negative cable. Turn. the park
nuity. I f OK, go to Step 6. I f not OK, repair the igni lamps on with the headlamp switch. Rotate the head
tion switch case ground or replace the faulty ignition lamp switch knob counterclockwise to just before the
switch as required. interior lamps detent. Check for battery voltage at
(6) Remove the instrument cluster bezel and the the fused panel lamps dimmer switch signal circuit
cluster assembly. Connect the battery negative cable cavity of the right cluster connector. I f OK, go to Step
and the ignition switch connector. Do not unplug the 4. I f not OK, repair the open circuit as required.
cluster connectors. Install a jumper wire between the (4) Turn the park lamps off. Disconnect and Isolate
red brake warning lamp driver circuit cavity of the the battery negative cable. Remove the fuse from the
left cluster connector and a good ground. Turn the fuseblock module. Probe the fused panel lamps dim
Ignition switch to the On position. The lamp should mer switch signal circuit cavity of the right cluster
light. I f OK, go to Step 7. I f not OK, replace the connector. Check for continuity to a good ground.
faulty bulb. There should be no continuity. I f OK, go to Step 5. I f
(7) Turn the ignition switch to the Off position and not OK, repair the short circuit as required.
remove the jumper wire. Disconnect and isolate the (5) Check for continuity between the fused panel
battery negative cable. Unplug the ignition switch, lamps dimmer switch signal circuit cavity of the
parking brake switch, vacuum sensor (diesel engine right cluster connector and the output side of the
only) and brake warning switch connectors. Unplug fuse cavity. There should be continuity. I f OK, replace
the connector at the RWAL or ABS control module, as the faulty bulb(s). I f not OK, repair the open circuit
equipped. Unplug the left cluster connector. Check as required.
for continuity between the red brake warning lamp
driver circuit cavity of the left cluster connector and FOUR-WHEEL DRIVE INDICATOR LAMP
a good ground. There should be no continuity. I f OK, The diagnosis found here addresses an inoperative
go to Step 8. I f not OK, repair the short circuit as four-wheel drive indicator lamp condition. I f the
required. problem being diagnosed is related to lamp accuracy,
(8) Check for continuity between the red brake be certain to confirm that the problem is with the
warning lamp driver circuit cavities of the left cluster lamp or switch and not with a damaged or inopera
connector and the following connectors:, tive front axle disconnect. Refer to Group 2 - Front
• Parking brake switch Suspension and Axle for more information. I f no front
• Brake warning switch axle disconnect problem is found, the following proce
• Vacuum sensor (diesel engine'only) dure will help locate a short or open i n the indicator
• Ignition switch lamp circuit. For circuit diagrams and descriptions,
• RWAL control module refer to 8W-40 - Instrument Cluster i n Group 8W -
• ABS control module. Wiring Diagrams.
(9) I n each case there should be continuity. I f not (1) Turn the ignition switch to the On position.
OK, repair the open circuit as required. Unplug the four-wheel drive switch connector at the
front axle disconnect housing. Install a jumper wire
CLUSTER ILLUMINATION LAMPS between the two cavities in the switch connector. The
For circuit descriptions and diagrams, refer to lamp should light. Remove the jumper and the lamp
8W-40 - instrument Cluster in Group 8W - Wiring should go off. I f OK, replace the faulty four-wheel
Diagrams. drive switch. I f not OK, go to Step 2.
(1) Check the fuse in the fuseblock module. I f OK, (2) Turn the ignition switch to the Off position.
go to Step 2. i f not OK, replace the faulty fuse. Check for continuity between the ground circuit cav
(2) Turn the park lamps on with the headlamp ity of the four-wheel drive switch connector and a
switch. Rotate the headlamp switch knob counter good ground. There should be continuity. I f OK, go to
clockwise to just before the interior lamps detent. Step 3. I f not OK, repair the ground circuit as
Check for battery voltage at the fuse in the fuseblock required.

(3) Disconnect and isolate the battery negative right cluster connector. Probe the generator lamp
cable. Remove the instrument cluster bezel and the driver circuit cavity of the right cluster connector and
cluster assembly. Do not unplug the cluster connec check for continuity to a good ground. There should
tors. Connect the battery negative cable. Install a be no continuity. I f OK, go to Step 4. I f not OK,
jumper wire between the 4WD lamp circuit cavity of repair the short circuit as required.
the right cluster connector and a good ground. Turn (4) Check for continuity between the generator
the ignition switch to the On position. The lamp lamp driver circuit cavities of the right cluster con
should light. I f OK, go to Step 4. I f not OK, replace nector and the PCM connector C. There should be
the faulty bulb. continuity. I f not OK, repair the open circuit as
(4) Turn the Ignition switch to the Off position. required.
Unplug the right cluster connector, and the RWAL or HEADLAMP HIGH 1EAM INDICATOR LAMP
ABS control module connector. Probe the 4WD lamp The diagnosis found here addresses an inoperative
circuit cavity of the right cluster connector. Check for headlamp high beam indicator lamp condition. I f the
continuity to a good ground. There should be no con problem being diagnosed is related to inoperative
tinuity. I f OK, go to Step 5. I f not OK, repair the headlamp high beams, refer to Group 8L - Lamps for
short circuit as required. diagnosis of the headlamp system. I f no headlamp
(5) Check for continuity between the 4WD lamp system problems are found, the following procedure
circuit cavity of the right cluster connector and the will help locate an open in the high beam indicator
4WD sense circuit cavity of the four-wheel drive lamp circuit. For circuit descriptions and diagrams,
switch connector. There should be continuity. I f not refer to 8W-40 - Instrument Cluster in Group 8W -
OK, repair the open circuit as required. Wiring Diagrams.
(1) Check that the headlamp high beams are func
GENERATOR WARNING LAMP tional. I f OK, go to Step 2. I f not OK, refer to Group
The diagnosis found here addresses an inoperative 8L - Lamps for diagnosis of the headlamp system.
generator warning lamp condition. I f the generator (2) Disconnect and isolate the battery negative
warning lamp comes on or stays on with the engine cable. Remove the instrument cluster bezel and the
running, refer to Group 8C - Charging System for cluster assembly. Unplug the left cluster connector.
diagnosis. I f no charging system problem is found, Connect the battery negative cable. Turn the head
the following procedure will help locate a short or lamps on and select high beam. Check for battery
open in the generator warning lamp circuit. For cir voltage at the high beam indicator lamp driver cir
cuit descriptions and diagrams, refer to 8W-40 - cuit cavity of the left cluster connector. I f OK, replace
Instrument Cluster in Group 8W - Wiring Diagrams. the faulty bulb. I f not OK, repair the open circuit to
(1) Disconnect and isolate the battery negative the headlamp dimmer (multi-function) switch as
cable. Unplug the PCM connector C (gray). Install a required.
jumper wire between the generator lamp driver cir
cuit cavity of the PCM connector and a good ground. LOW FUEL WARNING LAMP
Connect the battery negative cable and turn the igni The diagnosis found here addresses an inoperative
tion switch to the On position. The lamp should light. low fuel warning lamp condition. I f the problem
Unplug the jumper wire and the lamp should go off. being diagnosed is related to lamp accuracy, be cer
If OK, refer to the Powertrain Diagnostic Procedures tain to confirm the problem is the with the low fuel
to check the PCM. I f not OK, go to Step 2. warning lamp and not with the fuel gauge circuit.
(2) Turn the ignition switch to the Off position. See the diagnosis for the Fuel Gauge in this group. I f
Disconnect and isolate the battery negative cable. no fuel gauge problem is found, the following proce
The PCM connector C is still unplugged. Remove the dure will help to identify a faulty low fuel warning
instrument cluster bezel and the instrument cluster. lamp circuit. For circuit descriptions and diagrams,
Do not unplug the cluster connectors. Install a refer to 8W-40 - Instrument Cluster i n Group 8W -
jumper wire between the generator lamp driver cir Wiring Diagrams.
cuit cavity of the right cluster connector and a good (1) Check that the fuel gauge is operating as
ground. Connect the battery negative cable and turn designed. See the Fuel Gauge Calibration chart in
the ignition switch to the On position. The lamp Specifications. I f OK, go to Step 2. I f not OK, see
should light. I f OK, go to Step 3. I f not OK, replace Fuel Gauge in this section for diagnosis.
the faulty bulb. (2) Disconnect and isolate the battery negative
(3) Turn the ignition switch to the Off position. cable. Unplug the fuel pump module connector.
Disconnect and isolate the battery negative cable. Remove the instrument cluster bezel and the instru
The PCM connector C is still unplugged. Unplug the ment cluster. Replace the low fuel warning bulb with
8E - 1 4 INSTRUMENT PANEL SYSTEMS — — BR
a known good unit. Connect the battery negative
cable and test the lamp operation. I f OK, discard the
faulty bulb. I f not OK, replace the faulty low fuel
warning printed circuit.
LOW OIL PRESSURE WARNING LAMP

The diagnosis found here addresses an inoperative
low oil pressure warning lamp condition. I f the prob
lem being diagnosed is related to lamp accuracy, be
certain to confirm that the problem is with the lamp
and not with the engine oiling system. The actual
engine oil pressure should be checked with a test
gauge before you proceed with lamp diagnosis. Refer
to Group 9 - Engines for more information. For cir
cuit descriptions and diagrams, refer to 8W-40 -
Instrument Cluster in Group 8W - Wiring Diagrams.
(1) Turn ignition the switch to the On position.
Disconnect the oil pressure sending unit connector
(Fig. 7), (Fig. 8) or (Fig. 9). Install a jumper wire
between the oil pressure switch sense circuit cavity
of the sending unit connector and a good ground. The
lamp should light. Remove the jumper wire and the
lamp should go off. I f OK, replace the faulty sending Fig. 8 Oii Pressure Switch/Sending Unit - V-10
unit. I f not OK, go to Step 2. Engine
Fig. 7 Oii Pressure Switch/Sending Unit - V-6/V-8

Engine
(2) Turn the ignition switch to the Off position. PUMP ENGINE BLOCK
Remove the instrument cluster bezel and the cluster Fig. 9 Oii Pressure Switch/Sending Unit - Diesei
assembly. Disconnect the right cluster connector. Engine
(3) Probe the oil pressure switch sense circuit cav should be continuity. I f OK, replace the faulty bulb.
ity of the right cluster connector and check for conti I f not OK, repair the open circuit as required.
nuity to a good ground. There • should be no
continuity. I f OK, go to Step 4. I f not OK, repair the LOW WASHER FLUID WARNING LAMP
short circuit as required. The diagnosis found here addresses an inoperative
(4) Check for continuity between the oil pressure low washer fluid warning lamp condition. If the prob
switch sense circuit cavities of the right cluster con lem being diagnosed is related to lamp accuracy, be
nector and the sending unit wire connector. There certain to confirm that the problem is with the lamp
or switch and not with a damaged or empty washer

fluid reservoir. Inspect the reservoir for proper fluid Unplug the message center connector. Check for con
level and signs of damage or distortion that could tinuity between the service reminder indicator lamp
affect switch performance before you proceed with driver circuit cavity of the message center connector
lamp diagnosis. Refer to Group 8K - Wiper and and a good ground. There should be no continuity. I f
Washer Systems for more information. For circuit OK, go to Step 4. I f not OK, repair the short circuit
descriptions and diagrams, refer to 8W-40 - Instru as required.
ment Cluster in Group 8W - Wiring Diagrams. (4) Check for continuity between the service
(1) Unplug the washer fluid level switch connector. reminder indicator lamp driver circuit cavities of the
Install a jumper wire between the two cavities of the message center connector and the PCM connector C.
connector. Turn the ignition switch to the On posi There should be continuity. I f OK, refer to Group 14 -
tion. The lamp should light. Remove the jumper wire Fuel Systems for diagnosis of the PCM. I f not OK,
and the lamp should go off. I f OK, replace the faulty repair the open circuit as required.
washer fluid level switch. I f not OK, go to Step 2.
(2) Turn the ignition switch to the Off position. MALFUNCTION INDICATOR LAMP
Check for continuity between the washer fluid level The diagnosis found here addresses an inoperative
switch connector ground circuit cavity and a good malfunction indicator lamp condition. I f the lamp
ground. There should be continuity. I f OK, go to Step comes on and stays on with the engine running, refer
3. I f not OK, repair the open circuit as required. to Group 14 - Fuel System for diagnosis. I f no fuel or
(3) Disconnect and isolate the battery negative emission system problem is found, the following pro
cable. Remove the instrument cluster bezel and the cedure will help locate a short or open i n the lamp
cluster assembly. Unplug the right instrument clus circuit. For circuit descriptions and diagrams, refer to
ter connector. Check for continuity between the 8W-40 - Instrument Cluster in Group 8W - Wiring
washer fluid switch sense circuit cavity of the right Diagrams.
cluster connector and a good ground. There should be (1) Disconnect and isolate the battery negative
no continuity. I f OK, go to Step 4. I f not OK, repair cable. Unplug the Powertrain Control Module (PCM)
the short circuit as required. connector C (gray). Install a jumper wire between the
(4) Check for continuity between the washer fluid malfunction indicator lamp driver circuit cavity of
switch sense circuit cavities of the right cluster con the PCM connector C and a good ground. Connect
nector and the washer fluid level switch connector. the battery negative cable. Turn the ignition switch
There should be continuity. I f OK, replace the faulty to the On position. The lamp should light. Remove
bulb. I f not OK, repair the open circuit as required. the jumper wire and the lamp should go off. I f OK,
refer to the Powertrain Diagnostic Procedures to
MAINTENANCE REQUIRED INDICATOR LAMP diagnose the PCM. I f not OK, go to Step 2.
The diagnosis found here addresses an inoperative (2) Turn the ignition switch to the Off position.
maintenance required indicator lamp condition. If the Disconnect and isolate the battery negative cable.
lamp comes on and stays on while driving, refer to Remove the instrument cluster bezel and the cluster
Group 25 - Emission Control Systems for diagnosis. assembly. Do not unplug the cluster connectors.
If no emission control system problem is found, the Install a jumper wire between the malfunction indi
following procedure will help locate a short or open cator lamp driver circuit cavity of the right cluster
in the indicator lamp circuit. For circuit descriptions connector and a good ground. Connect the battery
and diagrams, refer to 8W-46 - Message Center in negative cable. Turn the ignition switch to the On
Group 8W - Wiring Diagrams. position. The lamp should light. I f OK, go to Step 3.
(1) Disconnect and isolate the battery negative If not OK, replace the faulty bulb.
cable. Unplug the Powertrain Control Module (PCM) (3) Turn the ignition switch to the Off position.
connector C (gray). Remove the instrument cluster Disconnect and isolate the battery negative cable.
bezel and the message center assembly. Do not Unplug the right cluster connector. Check for conti
unplug the message center connector. nuity between the malfunction indicator lamp driver
' (2) Install a jumper wire between the service circuit cavity of the right cluster connector and a
reminder indicator lamp driver circuit cavity of the good ground. There should be no continuity. I f OK, go
message center connector and a good ground. Con to Step 4. I f not OK, repair the short circuit as
nect the battery negative cable. Turn the ignition required.
switch to the On position. The lamp should light. I f (4) Check for continuity between the malfunction
OK, remove the jumper wire and go to Step 3. I f not indicator lamp driver circuit cavities of the right
OK, replace the faulty bulb. cluster connector and the PCM connector C. There
(3) Turn the ignition switch to the Off position. should be continuity. I f not OK, repair the open cir
Disconnect and isolate the battery negative cable. cuit as required.
8E - 1 6 INSTRUMENT PANEL SYSTEMS

SEAT BELT REMINDER LAMP cuit cavity of the message center connector. I f OK, go
The diagnosis found here addresses an inoperative to Step 2. I f not OK, repair the open circuit as
seat belt reminder lamp condition. I f the lamp comes required.
on and stays on, refer to Group 8U - Chime/Buzzer (2) Turn the ignition switch to the Off position.
Warning Systems for diagnosis. I f no warning system Install a jumper wire between the transmission tem
problem is found, the following procedure will help perature lamp driver circuit cavity of the message
locate a short or open in the lamp circuit. For circuit center connector and a good ground. Turn the igni
descriptions and diagrams, refer to 8W-40 - Instru tion switch to the On position. The lamp should light.
ment Cluster in Group 8W - Wiring Diagrams. I f OK, go to Step 2. I f not OK, replace the faulty
(1) Disconnect and isolate the battery negative bulb.
cable. Remove the instrument cluster bezel and the (3) Turn the ignition switch to the Off position.
cluster assembly. Unplug the left cluster connector. Disconnect and isolate the battery negative cable.
Check for continuity between the ground circuit cav Unplug the message center connector, and the Pow
ity of the left cluster connector and a good ground. ertrain Control Module (PCM) connector C (gray).
There should be continuity. I f OK, plug the left clus Check for continuity between the transmission tem
ter connector back into the cluster and go to Step 2. perature lamp driver circuit cavity of the message
If not OK, repair the open circuit as required. center connector and a good ground. There should be
(2) Connect the battery negative cable. Install a no continuity. I f OK, go to Step 4. I f not OK, repair
jumper wire between a 12-volt battery feed source the short circuit as required.
and the seat belt lamp driver circuit cavity of the left (4) Check for continuity between the transmission
cluster connector. The lamp should light. I f OK, go to temperature lamp driver circuit cavities of the mes
Step 3. I f not OK, replace the faulty bulb. sage center connector and the PCM connector C.
(3) Disconnect and isolate the battery negative There should be continuity. I f OK, refer to Group 21 -
cable. Unplug the chime/buzzer module from the Transmission to diagnose the temperature sensor and
buzzer module connector. Unplug the left cluster con circuit. I f not OK, repair the open circuit as required.
nector. Check for continuity between the seat belt
lamp driver circuit cavity of the left cluster connector TURN SIGNAL INDICATOR LAMPS
and a good ground. There should be no continuity. I f The diagnosis found here addresses an inoperative
OK, go to Step 4. I f not OK, repair the short circuit turn signal indicator lamp condition. For any other
as required. turn signal problem, refer to Group 8J - Turn Signal
(4) Check for continuity between the seat belt and Hazard Warning Systems for diagnosis. I f no
lamp driver circuit cavities of the left cluster connec turn signal or hazard warning system problem is
tor and the buzzer module connector. There should be found, the following procedure will help locate a
continuity. I f not OK, repair the open circuit as short or open i n the indicator lamp circuit. For cir
required. cuit descriptions and diagrams, refer to 8W-40 -
Instrument Cluster and 8W-50 - Front Lighting in
TRANSMISSION OIL TEMPERATURE WARNING Group 8W - Wiring Diagrams.
LAMP (1) Disconnect and isolate the battery negative
The diagnosis found here addresses an inoperative cable. Remove the instrument cluster bezel and the
transmission oil temperature warning lamp condi cluster assembly. Do not unplug the cluster connec
tion. I f the problem being diagnosed is related to tors. Probe the ground circuit cavities of the left clus
lamp accuracy, be certain to confirm that the problem ter connector. Check for continuity to a good ground.
is with the lamp and not with the transmission oil There should be continuity. I f OK, go to Step 2. I f not
cooling system. Proper transmission oil flow and OK, repair the open circuit(s) as required.
cooler operation should be checked before you pro (2) Connect the battery negative cable. Install a
ceed with lamp diagnosis. For diagnosis and service jumper wire from the inoperative (right or left) turn
of the sensor and transmission oil cooling system, signal circuit cavity of the left cluster connector to a
refer to Group 21 - Transmission. For circuit descrip 12-volt battery feed source. The lamp should light. I f
tions and diagrams, refer to 8W-46 - Message Center OK, go to Step 3. I f not OK, replace the faulty bulb.
in Group 8W - Wiring Diagrams. (3) Disconnect and isolate the battery negative
(1) Disconnect and isolate the battery negative cable. Unplug the left cluster connector. Disconnect
cable. Remove the instrument cluster bezel and the the turn signal (multi-function) switch connector.
message center. Do not unplug the message center Check for continuity between the inoperative (right
connector. Connect the battery negative cable. Turn or left) turn signal circuit cavities of the left cluster
the ignition switch to the On position. Check for bat connector and the multi-function switch connector.
tery voltage at the fused ignition switch output cir There should be continuity. I f OK, refer to Group 8J -
BR INSTRUMENT PANEL SYSTEMS 8E - 1 7
Turn Signal and Hazard Warning Systems for further (1) Disconnect and isolate the battery negative
diagnosis. I f not OK, repair the open circuit as cable. Remove the instrument cluster bezel and the
required. message center. Unplug the message center connec
tor.
UPSHIFT INDICATOR LAMP (2) Connect the battery negative cable. Turn the
The diagnosis found here addresses an Inoperative Ignition switch to the ON position. Check for battery
upshift indicator lamp condition. I f the lamp comes voltage at the fused ignition switch output circuit
on and stays on with the engine running, refer to cavity of the message center connector. I f OK, turn
Group 14 - Fuel System for diagnosis of the Power- the ignition, switch to the Off position and go to Step
train Control Module (PCM). I f no fuel or emission 3. i f not OK, repair the open circuit as required.
control systems problem is found, the following pro (3) Plug in the message center connector. Install a
cedure will help locate a short or open in the lamp jumper wire between the walt-to-start warning lamp
circuit. For circuit descriptions and diagrams, refer to driver circuit cavity of the message center connector
8W-40 - Instrument Cluster in Group 8W - Wiring and a good ground. Turn the ignition switch to the
Diagrams. On position. The lamp should light. I f OK, turn the
(1) Disconnect and isolate the battery negative Ignition switch to the Off position, remove the
cable. Unplug the PCM connector B (white). Connect jumper wire, and go to Step 4. i f not OK,' replace the
the battery negative cable. Turn the ignition switch faulty bulb.
to the On position. Install a jumper wire between the (4) Disconnect and isolate the battery negative
upshift lamp driver circuit cavity of the PCM connec cable. Unplug the message center connector and the
tor B and a good ground. The lamp should light. PCM connector B (white). Check for continuity
Remove the jumper wire and the lamp should go off. between the wait-to-start warning lamp driver circuit
If OK, refer to the Powertrain Diagnostic Procedures cavity of the message center connector and a good
manual to diagnose the PCM. I f not OK, turn the ground. There should be no continuity. I f OK, go to
ignition switch to the Off position and go to Step 2. Step 5. i f not OK, repair the short circuit as
(2) Disconnect and isolate the battery negative required.
cable. Remove the Instrument cluster bezel and the (5) Check for continuity between the wait-to-start
cluster assembly. Install a jumper wire between the warning lamp driver circuit cavities of the message
upshift lamp driver circuit cavity of the left cluster- center connector and the PCM connector B. There
connector and a good ground. Connect the battery should be continuity. I f OK, refer to Group 14 - Fuel
negative cable. Turn the ignition switch to the On System to diagnose the PCM and its inputs, i f not
position. The lamp should light. I f OK, go to Step 3. OK, repair the open circuit as required.
i f not OK, replace the faulty bulb.
(3) Turn the ignition switch to the Off position. WATER-IN-FUEL LAMP
Disconnect and Isolate the battery negative cable. The diagnosis found here addresses an inoperative
Unplug the left cluster connector. Check for continu water-in-fuel lamp condition, i f the lamp comes on
ity between the upshift lamp driver circuit cavity of and stays on while driving, refer to Group 14 - Fuel
the left cluster connector and a good ground. There System for diagnosis, i f no problem is found with the
should be no continuity. I f OK, go .to Step 4. I f not water-in-fuel sensor circuit or the Powertrain Control
OK, repair the short circuit as required. Module (PCM), the following procedure will help
(4) Check for continuity between the upshift lamp locate a short or open in the lamp circuit. For circuit
driver circuit cavities of the left cluster connector and descriptions and diagrams, refer to 8W-46 - Message
the PCM connector B. There should be continuity. I f Center in Group 8W - Wiring Diagrams.
not OK, repair the open circuit as required. (1) Disconnect and Isolate the battery negative
cable. Remove the Instrument cluster bezel and the
WAIT-TO-START LAMP message center. Unplug the message center connec
The diagnosis found here addresses an Inoperative tor.
wait-to-start lamp condition. I f the lamp comes on (2) Connect the battery negative cable. Turn the
and stays on while driving or flashes, refer to Group ignition switch to the On position. Check for battery
14 - Fuel System for diagnosis, i f no problem is found voltage at the fused ignition switch output circuit
with the intake manifold air temperature sensor cir cavity of the message center connector. I f OK, turn
cuit or the Powertrain Control Module (PCM), the the ignition switch to the Off position and go to Step
following procedure will help locate a short or open 3. I f not OK, repair the open circuit as required.
in the lamp circuit. For circuit descriptions and dia (3) Plug i n the message center connector. Install a
grams, refer to 8W-46 -Message Center i n Group 8W jumper wire between the water-in-fuel warning lamp
- Wiring Diagrams. driver circuit cavity of the message center connector
and a good ground. Turn the ignition switch to the
On position'. The lamp should light. I f OK, turn the
ignition switch to the Off position, remove the
jumper wire, and go to Step 4. I f not OK, replace the
faulty bulb.
cable. Unplug the message center connector and the
PCM connector C (gray). Check for continuity
between the water-in-fuel warning lamp driver cir
cuit cavity of the message center connector and a
J948E-8
good ground. There should be no continuity. I f OK, go
to Step 5. I f not OK, repair the short circuit as Fig. 11 Cup Holder Remove/Install
required.
(5) Check for continuity between the water-in-fuel
warning lamp driver circuit cavities of the message
center connector and the PCM connector C. There
should be continuity. I f OK, refer to Group 14 - Fuel
Systems to diagnose the PCM and its inputs. I f not
OK, repair the open circuit as required.
R E M O V A L AND INSTALLATION
ASH RECEIVER
(1) Remove the ash receiver.
(2) Remove the two screws securing the ash
receiver bracket to the instrument panel (Fig. 10).
J948E-1
J Fig. 12 Knee Blocker Remove/Install

FUSEBLOCK MODULE
cable.
(2) Remove the knee blocker as described in this
group.
J948E-9
(3) Remove the two screws holding the fuseblock
Fig. 10 Ash Receiver Remove/lnstaii module to the instrument panel (Fig. 13).
(4) Remove the fuseblock module from the instru
(3) Remove the ash receiver bracket assembly from ment panel.
the instrument panel. (5) Reverse the removal procedures to install.
INSIDE HOOD RELEASE
CUP HOLDER (1) Disengage the inside hood release cable from
(1) Open the cup holder and remove the two the hood latch in the engine compartment.
screws securing the assembly to the instrument (2) Remove the two screws holding the hood
panel (Fig. 11). release handle assembly to the lower instrument
(2) Remove the cup holder assembly from the panel support.
instrument panel. (3) Remove the assembly by pulling the cable and
(3) Reverse the removal procedures to install. grommet through the dash panel from the passenger
compartment.
KNEE BLOCKER (4) Reverse the removal procedures to install.
(1) Remove the five screws securing the knee
blocker to the lower instrument panel (Fig. 12).
(2) Remove the knee blocker from the lower instru
ment panel.
BR INSTRUMENT PANEL SYSTEMS 8E - 1 9
CIGAR LIGHTER/POWER OUTLET

(1) Remove the cluster bezel as described in this
group.
(2) Unscrew the cigar lighter and/or power outlet
housing from the rear of the cluster bezel (Fig. 15).
ELECTRICAL
CONNECTOR
CLIPS
REMOVE J948E-10
2 SCREWS J948U-2
Fig. 15 Cigar Lighter Remove/Install

Fig. 13 Fuseblock Module Remove/Install
(3) Remove the cigar lighter and/or power outlet
CLUSTER BEZEL from the front of the cluster bezel.
(1) Disconnect and isolate the battery negative (4) Reverse the removal procedures to install.
cable.
(2) Remove the cup holder as described in this INSTRUMENT CLUSTER
group. (1) Remove the cluster bezel as described in this
(3) Remove the ash receiver as described in this group.
group. (2) Remove the knee blocker as described in this
(4) Carefully pry the bezel away from the Instru group.
ment panel to disengage the retaining clips (Fig. 14). (3) Pull the gear selector indicator (PRND21) cable
and twist to remove from the position arm on the
steering column, i f equipped (Fig. 16).
PRNDL
CABLE
POSITION
ARM
J948E-46 STEERING
PUSH TAB COLUMN
UP
Fig. 14 Cluster Bezel Remove/install J948E-4
(5) Unplug the connector from the cigar lighter. Fig. 16 PRND21 Cable Remove
(6) Unplug the connector from the auxiliary power
outlet. (4) Push the tab on the bottom of the cable
(7) Reverse the removal procedures to install. retainer up, then squeeze the sides to remove the
retainer from the steering column.
8E - 20 INSTRUMENT PANEL SYSTEMS
mm
R E M O V A L AMD I N S T A L L A T I O N fContinued)
(5) Remove the four screws that hold the cluster to REMOVE SCREWS
the instrument panel (Fig. 17).
REMOVE SCREWS — J948E-13
Fig. 19 Cluster Lens Remove/Install
LENS.
GAUGE
J948E-11 BEZEL
Fig. 17 instrument Cluster Remove/Install

MOUNTING BEZEL
(6) Pull the cluster rearward and unplug the two AND G A U G E S
cluster electrical connectors (Fig. 18).
PRND21
CABLE
RETAINER
INSTRUMENT CLUSTER
J948E-12
J948E-14
Fig, 18 Cluster Connectors
Fig. 20 Instrument Cluster Assembly
(7) Remove the cluster from the instrument panel.
(8) Reverse the removal procedures to install. (4) Reverse the removal procedures to install.
Refer to Group 21 - Transmission for the gear selec
tor indicator (PRND21) cable adjustment procedure. GAUGES
(1) Remove the cluster lens and mask as described
CLUSTER LENS AND MASK in this group.
(1) Remove the instrument cluster as described in (2) Remove the screws securing the gauge unit(s)
this group. from the rear of the cluster housing (Fig. 21) or (Fig.
(2) Remove the seven screws securing the lens and 22). Remove the gauge unit from the front of the
mask to the cluster housing (Fig. 19). cluster housing.
(3) Remove the cluster lens and the gauge mask
(Fig. 20). CAUTION: Do not overtighten the gauge mounting
screws or damage to the printed circuit and/or the
NOTE: Do not touch the face of a gauge or the cluster housing will occur.
back of the lens with your finger. It will leave a per
manent finger print. (3) Reverse the removal procedures to install.
BR — — — — — — — — — — — INSTRUMENT PANEL SYSTEMS 8E - 21
SPEEDOMETER TACHOMETER
SCREWS SCREWS
VOLTMETER
SCREWS
OIL PRESSURE
GAUGE SCREWS
COOLANT FUEL GAUGE

TEMPERATURE SCREWS
GAUGE
© AIR BAG
SCREWS
(D ILLUMINATION
( f ) TURN SIGNAL INDICATORS
® HIGH BEAM INDICATOR
( ? ) LOW FUEL
J948E-22
Fig. 21 Gauge Mounting • High-Line Cluster
VOLTMETER SPEEDOMETER FUEL GAUGE
SCREWS SCREWS SCREWS
• OIL PRESSURE
GAUGE SCREWS
7. UPSHIFT INDICATOR
1. ILLUMINATION 8. SEAT BELT WARNING LAMP
2. TURN SIGNAL INDICATORS 9. MALFUNCTION INDICATOR
3. HIGH BEAM INDICATOR (CHECK ENGINE)
4. ABS 10. LOW OIL INDICATOR
5. MAINTENANCE INDICATOR 11. AIRBAG
6. BRAKE 12. 4WD INDICATOR J948E-45
Fig. 22 Gauge Mounting - Low-Line Cluster
GEAR SELECTOR INDICATOR
(1) Remove the instrument cluster as described in
this group.
(2) Remove the screws attaching the gearshift
selector (PRND21) indicator mechanism to the rear
of the cluster housing (Fig. 23).
INSTRUMENT
CLUSTER
© O FUEL CIRCUIT
CONNECTOR J948E-59
Fig. 24 Low Fuel Warning Circuit Connector

(4) Pull the flexible printed circuit back away from
the rear of the cluster housing.
(5) Remove the low fuel warning circuit.
PRND2I
HOUSING
PRINTED CIRCUIT
(1) Remove the instrument cluster as described in
this group.
(2) Remove all of the cluster bulb lamp socket
J948E-50 assemblies as described in this group.
(3) I f equipped, remove the low fuel warning cir
Fig. 23 Gearshift Selector (PRND21) Indicator cuit as described in this group.
Housing Remove/Install (4) Remove all of the gauge units as described in
(3) Remove the gearshift selector indicator mecha this group.
nism from the cluster housing. (5) Remove the printed circuit from the rear of the
(4) Reverse the removal procedures to install. cluster housing.
Refer to Group 21 - Transmission for the gearshift
selector indicator cable adjustment procedure. CAUTION: Do not overtighten the gauge mounting
screws or damage to the printed circuit and/or the
CLUSTER BULBS cluster housing will occur.
(1) Remove the instrument cluster as described i n (6) Reverse the removal procedures to install.
this group.
(2) Twist the lamp socket assembly to remove i t OIL PRESSURE SENDING UNIT
from the printed circuit board on the rear of the clus (1) Unplug the connector from the sending unit.
ter housing. (2) Using the oil pressure sending unit socket
(3) Remove the bulb from the lamp socket. (Special Tool C-4597), remove the sending unit (Fig.
(4) Install the correct replacement bulb into the 25).
lamp socket. (3) Reverse the removal procedures to install.
(5) Reverse the removal procedures to install. Tighten the sending unit to 23 N-m (200 in. lbs.).
LOW FUEL WARNING CIRCUIT VEHICLE SPEED SENSOR
(1) Remove the instrument cluster as described i n (1) Remove the harness connector from the sensor.
this group. Be sure the weather seal stays on the harness con
(2) Remove the low fuel warning circuit from the nector.
printed circuit connector on the rear of the cluster (2) Remove the sensor by loosening the sensor cou
housing (Fig. 24).
pling nut from the pinion gear adapter until the sen
(3) Remove the left turn signal bulb and cluster sor is free (Fig. 26).
illumination bulb.
BR — • • — — — — - INSTRUMENT PANEL SYSTEMS 8E - IS
R E M O V A L A N D I N S T A L L A T I O N fContinued)
SPECIAL TOOL
C-4597
OIL PRESSURE
SENDING UNIT J948E-6
Fig. 27 Message Center and Heater-A/C Controi

Fig. 25 Oii Pressure Sending Unit Remove/instail
Remove/tnstaii
SPEEDOMETER (4) Unplug the two wiring harness connectors from
PINION G E A R the rear of the message center and heater-A/C con
ELECTRICAL trol assembly (Fig. 28).
CONNECTOR
O-RING
SENSOR
MOUNTING
BOLT
SPEEDOMETER PINION
GEAR ADAPTER
VEHICLE J948E-7
O-RING
SPEED
SENSOR J9314-188 Fig. 28 Message Center and Heater-A/C Controi
Connectors
Fig. 26 Vehicie Speed Sensor Remove/instali
(5) Push in on the red temperature control cable
(3) Reverse the removal procedures to install. connector to release it from the heater-A/C control
Tighten coupling nut to 17 N-m (150 in. lbs.). housing. Remove the cable end from the control unit.
(6) Remove the message center and heater A/C
MESSAGE CENTER control assembly from the instrument panel.
(1) Remove the cluster bezel as described in this (7) Reverse the removal procedures to install.
group.
(2) Remove the four message center/heater-A/C MESSAGE CENTER BULBS
control attaching screws (Fig. 27). (1) Remove the message center as described i n this
(3) Pull the message center and heater-A/C control group.
assembly rearward.
m -M INSTRUMENT PANEL SYSTEMS BR
(2) Twist the lamp socket assembly to remove it KNOB A N D
from the printed circuit board on the rear of the mes STEM
sage center housing.
(3) Remove the bulb from the lamp socket.
(4) Install the correct replacement bulb into the
lamp socket.
HEADLAMP SWITCH
WARNING: IF THE HEADLAMP SWITCH WAS

TURNED ON, WAIT FIVE MINUTES TO ALLOW THE
CERAMIC PANEL LAMPS DIMMER RESISTOR TO
COOL. IF T H E RESISTOR IS NOT ALLOWED TO
COOL, IT CAN BURN YOUR FINGERS, J948E-16
(1) Remove the cluster bezel as described in this

Fig. 30 Headlamp Switch Knob and Stem Remove/
group.
Install
(2) Remove the three screws securing the head
lamp switch bezel to the instrument panel (Fig. 29). OVERDRIVE LOCKOUT/FOG LAMP
SWITCH BEZEL
J958E-47
Fig. 31 Overdrive Lockout/Fog Lamp Switch

Remove/Install
Fig. 29 Headlamp Switch and Bezel Remove/install
(3) From the rear of the switch and bezel unit, pull
(3) Remove the headlamp switch and bezel from up on the retaining tab(s) and unplug the electrical
the instrument panel. connector(s).
(4) Unplug the two harness connectors from the (4) Release the retaining tabs and remove the
headlamp switch (Fig. 30). switch(es) from the rear of the bezel.
(5) Pull the headlamp switch knob and stem (5) Reverse the removal procedures to install.
assembly out to its stop. Depress the release button
on the bottom of the switch housing and remove the GLOVE BOX
knob and stem from the switch. (1) Open the glove box door. Depress the right side
(6) Remove the two screws and the switch bezel of the glove box bin far enough to allow the door stop
from the housing. to clear the glove box opening (Fig. 32).
(7) Reverse the removal procedures to install. (2) From inside of the glove box, push on the stem
of the button holding the retaining strap at the left
OVERDRIVE LOCKOUT/FOG LAMP SWITCH end of the door. The button will push out allowing
(1) Remove the cluster bezel as described in this the strap to be removed.
group. (3) The glove box door and bin are removed by lift
(2) Remove the three screws from the switch bezel ing the door off of the hinges (Fig. 33).
and remove the switch and bezel unit from the (4) Reverse the removal procedures to install.
instrument panel (Fig. 31).
BR . INSTRUMENT PANEL SYSTEMS 8E - 25
REMOVE
SCREWS
> GLOVE BOX

LAMP SWITCH
5-*~ GLOVE BOX
Fig. 32 Glove Box Door Release Fig. 34 Glove Box Lamp/Switch/Latch Striker -
Typical
Fig. 33 Glove Box and Bin Remove/Install

GLOVE BOX LAMP/SWITCH/LATCH STRIKER
cable.
(2) Open the glove box door until the door stops In
the bin rest against the instrument panel glove box
opening.
(3) To remove the lamp and switch, grasp the Fig. 35 Glove Box Lamp/Switch Connections -
switch by the plunger and pull firmly outward. The Typical
switch and lamp assembly are retained i n the mount GLOVE BOX LATCH
ing hole by a light snap fit. (1) Open the glove box door.
(4) To remove the latch striker, remove the two (2) Remove the glove box latch retaining clip.
mounting screws (Fig. 34). (3) Remove the glove box latch from the glove box
(5) Disconnect the wires to the switch and lamp door.
(Fig. 35). (4) Reverse the removal procedures to install.
(6) Remove the bulb from the lamp socket.
NOTE: Tuck any wiring that was exposed by the

lamp removal procedure back into the recess
behind the lamp. Do not leave wires exposed in the
glove box latch area.
8E - 26 INSTRUMENT PANEL SYSTEMS
INSTRUMENT PANEL ASSEMBLY

PRNDL
CABLE
WARNING: ON VEHICLES EQUIPPED WITH AN AIR-
POSITION
BAG, REFER TO GROUP 8M - PASSIVE RESTRAINT ARM
SYSTEMS BEFORE ATTEMPTING AIRBAG SYSTEM OR
STEERING WHEEL COMPONENT DIAGNOSIS OR SER
VICE. FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY
MENT AND POSSIBLE PERSONAL INJURY.

cable.
(2) Remove the left and right cowl side panel trim. STEERING
(3) Remove the knee blocker as described in this PUSH TAB . COLUMN
UP
group. J948E-4
(4) Remove the two screws securing the inside Fig. 37 Gearshift Indicator (PRND21) Cable Remove
hood release handle to the lower instrument panel
STEERING TILT UPPER PANEL
support.
WHEEL LEVER SHROUD BRACKET
(5) Remove the screw securing the parking brake
release handle to the lower instrument panel sup
port.
NUT
(6) Remove the six retaining screws and the lower
instrument panel support (Fig. 36).
SPACER
CLOCK SPRING
LOWER INSTRUMENT
PANEL SUPPORT
LOWER
N U T
SHROUD J928J-2
Fig. 38 Steering Column Shrouds
STEERING
Fig. 36 Lower instrument Panel Support Remove/Install COLUMN
ASSY.
(7) Unplug the airbag wiring connector at the
lower left corner of the instrument panel.
(8) Pull the gearshift selector (PRND21) indicator
cable and twist to remove i t from the position arm on
the steering column (Fig. 37).
(9) Push tab on bottom of cable retainer up then
squeeze sides to remove retainer from column.
(10) Remove the tilt steering column lever, i f
equipped.
(11) Remove the upper and lower shrouds from the TURN SIGNAL
steering column (Fig. 38). MULTI SWITCH A N D
F U N C T I O N LEVER
(12) Remove the lower fixed steering column shroud.
SWITCH
(13) Loosen the multi-function switch connector J918J-1 CONNECTOR
screw. The screw will remain in the connector.
Fig. 39 Multi-Function Switch Connector -Typical
Remove the multi-function switch connector (Fig. 39).
INSTRUMENT PANEL SYSTEMS 8E - 27

(14) Remove the other steering column connectors
(Fig. .40).
KEY-IN SWITCH & MULTI-FUNCTION
Fig. 42 Steering Column Mounting
Fig. 40 Steering Column Connectors

(15) Remove airbag wiring harness from the steer
ing column wiring trough.
(16) Remove the wiring trough from the steering
column.
(17) Remove the three steering column toe plate
nuts and washers (Fig. 41).
Fig. 43 Airbag Control Module Cower Screws
Fig. 41 Steering Column Toe Plate

(18) Remove the two nuts and washers attaching
the steering column bracket to the Instrument panel
steering column support bracket (Fig. 42).
(19) Lower the steering column and allow It to rest MODULE
on the seat.
(20) Remove the two screws from the bottom of the J948M-2
Airbag Control Module (ACM) cover (Fig. 43).

(21) Remove the four screws holding the ACM to Fig. 44 Airbag Control Module Remove/Install
the transmission tunnel on the floor (Fig. 44).
(22) Disconnect the wiring at the ACM.

(23) Disconnect the wiring connectors at the left (33) Reverse the removal procedures to install. Be
end of the instrument panel. certain that all wiring and hoses are not pinched.
(24) Remove the screw holding the parking brake Refer to Group 8M - Restraint Systems before con
release to the bottom of the instrument panel. necting the battery negative cable. Tighten the hard
(25) Disconnect the wiring connectors at the right ware as follows:
end of the instrument panel. There are: • Instrument panel upper mounting screws - 3
• Two connectors attached to the heater-A/C hous N-m (28 in. lbs.)
ing • Instrument panel pivot bolts - 12 N-m (110 in.
• Courtesy lamp connector lbs.)
• Antenna cable connector • Steering column shroud screws - 2 N-m (17 in.
• Two body harness connectors lbs.)
• Vacuum harness for heater-A/C system. • Steering column bracket nuts - 12 N-m (110 in.
(26) Remove the five - screws holding the instru lbs.)
ment panel to the dash panel. • Toe plate nuts - 23 N-m (200 in. lbs.)
(27) Remove the lower center instrument panel • Multi-function switch connector screw - 2 N-m
mounting screw. (17 in. lbs.)
(28) Loosen the lower instrument panel pivot bolts. • ACM mounting bolts - 11 N-m (105 in. lbs.)
(29) Roll the instrument panel down.
. (30) Using a screwdriver or pointed tool, push
through the plastic flashing to release the locking tab
on heater-A/C temperature control cable (Fig. 45).
LOCKING
Fig. 45 Heat-A/C Temperature Controi Cable

Remove
(31) Pull the temperature control cable from the
top of the heater-A/C housing.
(32) Remove the instrument panel from the vehi
cle.
SPECIFICATIONS
GAUGE CALIBRATION
Fuel Gauge Calibration Tachometer Calibration

Pointer Position Resistance Engines Pointer Position Frequency
Empty Graduation l-6,V-6,V-8 3000 rpm (±200) 100 Hz
97 ohms
(±2.5°) V-10 3000 rpm (±200) 125 Hz
Full Graduation
9 ohms
(±2.5°)
1/2 Graduation Temperature Gauge Calibration
32.5 ohms
(±5°)
Engine Pointer Position Resistance
Low Fuel Warning Indicator Low Normal
Gas 361.7 ohms
(±3°)
Delay
Sending Unit Resistance Lamp High Normal
Time Gas 77 ohms
(±3°)
65.4 ohms 8 to 30
On or Off Low Normal
(+5.3 / -5.0) seconds Diesel 155 ohms
(±3°)
High Normal
Oil Pressure Gauge Calibration Diesel 80.9 ohms
(±4°)
Pointer Position Resistance
Low Normal
65 ohms
(±3°) Voltmeter Calibration
High Normal
24.5 ohms Pointer Position Input Voltage
(±4°)
11,75 Graduation
12 volts
(±3°)
Speedometer Calibration
15.80 Graduation
Pointer Position Frequency 16 volts
(±4°)
20 mph (±3.0) 41.1 Hz
55 mph (±2.5) 118.8 Hz
75 mph (±2.5) 163.2 Hz
AUDIO SYSTEMS 8F - 1
AUDIO SYSTEMS
CONTENTS
page page
GENERAL INFORMATION AUDIO SYSTEM 3

INTRODUCTION 1 FILTER CHOKE/SPEAKER RELAY 5
DESCRIPTION AND OPERATION RADIO FREQUENCY INTERFERENCE 6
ANTENNA 2 RADIO 4
FILTER CHOKE/SPEAKER RELAY 1 SPEAKERS 4
IGNITION-OFF DRAW FUSE 1 REMOVAL AND INSTALLATION
RADIO NOISE SUPPRESSION 2 ANTENNA 9
RADIOS 1 FILTER CHOKE/SPEAKER RELAY 9
SPEAKERS 1 RADIO 6 r~
DIAGNOSIS AND TESTING SPEAKERS 7 " '
ANTENNA 5
G E N E R A L INFORMATION position can cause the radio display to become scram

bled when the IOD fuse is removed and replaced.
INTRODUCTION Removing and replacing the IOD fuse again, with the
Following are general descriptions of the major ignition switch in the Off position, will correct the
components used in both the standard and optional scrambled display condition.
equipment audio systems. Refer to 8W-47 Audio Sys The IOD fuse should be checked i f the radio station
tem in Group 8W - Wiring Diagrams for complete cir preset memory or clock functions are erratic or inop
cuit descriptions and diagrams. erative. The IOD fuse is located in the fuseblock
module. Refer to the fuseblock module label for IOD
fuse identification and location.
D E S C R I P T I O N A N D ©PEftA¥l©N
SPEAKERS
RADIOS Speaker system options include two or four
Radio options include an AM/FM, an AM/FM/cas- speaker locations. On two-speaker systems, one full-
sette, an AM/FM/CD, or an AM/FM/cassette with range speaker is located in each front door. Four-
graphic equalizer. All receivers are stereo Electroni speaker systems add one full-range speaker in each
cally Tuned Radios (ETR) and include a clock func rear cab side panel.
tion. For more information on radio features, setting The premium speaker option upgrades all the
procedures, and control functions refer to the Sound speakers in the above locations to Infinity bi-ampli-
System manual. The Sound System manual is fied models. Infinity coaxial speakers are mounted in
included with the owner's manual in the vehicle the rear cab side panels. Each front door has two
glove box. separate Infinity speakers, a woofer and a tweeter.
Each Infinity woofer features an integral amplifier
IGNITION-OFF DRAW FUSE and frequency filter unit. The amplifier of the radio
All vehicles are equipped with an Ignition-Off is used to drive the tweeters at each speaker loca
Draw (IOD) fuse that is removed when the vehicle is tion. The speaker-mounted amplifiers drive the woof
shipped from the factory. This fuse feeds various ers at each speaker location.
accessories that require current when the ignition
switch is in the Off position, including the clock and FILTER CHOKE/SPEAKER RELAY
radio station preset memory functions. The fuse is Models equipped with the Infinity premium
removed to prevent battery discharge during vehicle speaker package use this choke/relay to control bat
storage. tery feed to the speaker-mounted amplifiers. The
When removing or installing the IOD fuse, i t is choke/relay is mounted to the center lower instru
important that the ignition switch be in the Off posi ment panel brace to the right of the knee blocker
tion. Failure to place the ignition switch in the Off opening. The choke/relay can be accessed by remov-
8F - 2 AUDIO SYSTEMS BR
DESCRIPTION Mm OPERATION ( C o n t i n u e d )
ing the knee blocker. The choke/relay should be • Heater core ground strap (if equipped)
checked i f there is a lack of bass and low frequency • Resistor-type spark plugs
response noted at the rear cab side speakers, and no • Radio suppression-type secondary ignition wir
sound output at the front door woofers. ing.
In addition, i f the source of RFI or E M I noise is
ANTENNA identified as a component on the vehicle (i.e., gener
All models use a fixed-length stainless steel rod- ator, blower motor, etc.), the ground path for that
type antenna mast, installed at the right front fender component should be checked. - I f excessive resistance
of the vehicle. The antenna mast is connected to the is found in that circuit, repair that circuit as
center wire of the coaxial antenna cable and is not required before considering any component replace
grounded to any part of the vehicle. ment.
To eliminate static, the antenna base must have a I f the source of the noise is identified as two-way
good ground. The coaxial antenna cable shield (the mobile radio or telephone equipment, check the fol
outer wire mesh of the cable) is grounded to the lowing:
antenna base and the radio chassis. The antenna • Power connections should be made directly to
cable has an additional disconnect, located near the the battery, and fused as closely to the battery as
right end of the instrument panel and the right cowl possible.
side panel, to allow instrument panel installation • The antenna should be mounted on the roof or
and removal without removing the radio. toward the rear of the vehicle. Remember that mag
The factory-installed ETRs automatically compen netic antenna mounts on the roof panel can adversely
sate for radio antenna trim. Therefore, no antenna affect the operation of an overhead console compass
trimmer adjustment is required or possible when (if equipped).
replacing the receiver or the antenna. • Antenna cable should be fully shielded coaxial
cable, should be as short as is practical, and should
RADIO NOISE SUPPRESSION be routed away from the vehicle wiring whenever
Radio Frequency Interference (RFI) and Electro- possible.
Magnetic Interference (EMI) noise suppression is • The antenna and cable must be carefully
accomplished primarily through circuitry internal to matched to ensure a low Standing Wave Ratio
the radio receivers. These internal suppression (SWR).
devices are only serviced as part of the radio receiver. Fleet vehicles are available with an extra-cost RFI-
External suppression devices that are serviced, and suppressed Powertrain Control Module (PCM). This
should be checked in the case of RFI or E M I noise unit reduces interference generated by the PCM on
complaints, include the following: some radio frequencies used in two-way radio com
• Radio antenna base ground munications. However, this unit will not resolve com
• Radio chassis ground wire, strap, or bracket plaints of RFI in the commercial A M or FM radio
• Engine-to-body ground strap (if equipped) frequency ranges.
• Cab-to-bed ground strap (if equipped) ' .
BR AUDIO SYSTEMS 8F • 3
AUDIO SYSTEM
Audio System Diagnosis

NO AUDIO. 1. Fuse faulty. 1 Check radio fuses in fuseblock
2. Radio connector faulty. module. Replace fuses, if required.
3. Wiring faulty. 2. Check for loose or corroded radio
4. Ground faulty. connector. Repair, if required.
5. Radio faulty. 3. Check for battery voltage at radio
6. Speakers faulty. connector. Repair wiring, if required.
4. Check for continuity between radio
chassis and a known good ground.
There should be continuity. Repair
ground, if required.
5. Exchange or replace radio, if
required.
6. See speaker diagnosis, in this
group.
NO DISPLAY. 1. Fuse faulty. 1. Check radio fuses in fuseblock
2. Radio connector faulty. module. Replace fuses, if required.
connector. Repair wiring, if required.
required.
NO MEMORY. 1. Fuse faulty. 1. Check ignition-off draw fuse.
2. Radio connector faulty. Replace fuse, if required.
connector. Repair wiring, if required.
required.
POOR RADIO RECEPTION. 1. Antenna faulty. 1. See antenna diagnosis, in this
2. Ground faulty. group. Repair or replace antenna, if
3. Radio faulty. required.
ground, if required..
required.
8F - 4 AUDIO SYSTEMS — — —- BR
Audio System Diagnosis

NO/POOR TAPE OPERATION. 1. Faulty tape. • jfisert known good tape and test
2. Foreign objects behind tape door. operation.
3. Faulty tape deck. 2. Remove foreign objects and test
operation.
required.
NO COMPACT DISC OPERATION 1. Faulty CD. 1. Insert known good CD and test
2. Foreign material on CD. operation.
3. Condensation on CD or optics. 2. Clean CD and test operation.
4. Faulty CD player. 3. Allow temperature of vehicle interior
to stabilize and test operation.
4. Exchange or. replace radio, if
required.
RADIO SPEAKERS
For circuit descriptions and diagrams, refer to For circuit descriptions and diagrams, refer to
8W-47 - Audio System in Group 8W - Wiring Dia 8W-47 - Audio System in Group 8W - Wiring Dia
grams. grams.
CAUTION: The speaker output of the radio is a CAUTION: The speaker output of the radio is a
"floating ground" system. Do not allow any speaker "floating ground" system. Do not allow any speaker
lead to short to ground, as damage to the radio lead to short to ground, as damage to the radio
may result. may result.
(1) Check the fuse(s) in the fuseblock module and (1) Turn the radio on. Adjust the balance and fader
the Power Distribution Center (PDC). I f OK, go to controls to check the performance of each individual
Step 2. I f not OK, replace the faulty fuse(s). speaker. Note the speaker locations that are not per
(2) Check for battery voltage at the fuse in the forming correctly. Go to Step 2.
PDC. I f OK, go to Step 3. I f not OK, repair the open
circuit as required. NOTE: If the vehicle has the Infinity premium
(3) Turn the ignition switch to the On position. speaker package and the coaxial speakers lack
Check for battery voltage at the fuse i n the fuseblock bass or low frequency, while no response is noted
module. I f OK, go to Step 4. I f not OK, repair the at the woofers, see the diagnosis for the Filter
open circuit as required. Choke/Speaker Relay.
Disconnect and isolate the battery negative cable. (2) Turn the radio off. Disconnect and isolate the
Remove the instrument cluster bezel. Remove the battery negative cable. Remove the instrument clus
radio, but do not unplug any connections. Check for ter bezel and remove the radio. Check both the
continuity between the radio chassis and a good speaker feed (+) circuit and return (-) circuit cavities
ground. There should be continuity. I f OK, go to Step at the radio connectors for continuity to ground. In
5. I f not OK, repair the open circuit as required. each case, there should be no continuity. I f OK, go to
(5) Connect the battery negative cable. Turn the Step 3. I f not OK, repair the shorted speaker cir
ignition switch to the On position. Check for battery cuits) as required.
voltage at the fused ignition switch output circuit (3) I f equipped with the Infinity speaker system,
cavity of the left (gray) radio connector. I f OK, go to go to Step 5. I f equipped with the non-Infinity
Step 6. I f not OK, repair the open circuit as required. speaker system, check the resistance between the
(6) Turn the ignition switch to the Off position. speaker feed (+) circuit and return (-) circuit cavities,
Check for battery voltage at the fused B(+) circuit for each speaker location. The meter should read
cavity of the left (gray) radio connector. I f OK, between 3 and 8 ohms (speaker resistance). I f OK, go
replace the faulty radio. I f not OK, repair the open to Step 4. I f not OK, go to Step 5.
circuit as required. (4) Install a known good radio. Connect the bat
tery negative cable. Turn on the radio and test the
BR AUDIO SYSTEMS 8F • 5

speaker operation, i f OK, replace the faulty radio. I f for battery voltage at the amplified speaker (+) cir
not OK, disconnect and isolate the battery negative cuit cavity of the choke/relay connector. There should
cable, remove the test radio, and go to Step 5. be zero volts. Turn the Ignition and radio switches to
(5) Unplug the speaker wiring connector at the the On position. There should now be battery volt
speaker. Check for continuity between the speaker age. I f OK, repair the circuits from the choke/relay
feed (+) circuit cavities of the radio connector and the connector to the speaker amplifiers as required. I f
speaker connector. Repeat the check between the not OK, replace the faulty choke/relay.
speaker return (-) circuit cavities of the radio connec
tor and the speaker connector. In each case, there ANTENNA
should be continuity. I f OK with the Infinity speak The following four tests are used to diagnose the
ers, go to Step 6. I f OK with the non-Infinity speak antenna with an ohmmeter:
ers, replace the faulty speaker. I f not OK, repair the • Test 1 - Mast to ground test
open circuit(s) as required. • Test 2 - Tip-of-mast to tip-of-conductor test
(6) Check for continuity between the amplified • Test 3 - Body ground to battery ground test
speaker (-) circuit cavity of the body half of the • Test 4 - Body ground to coaxial shield test.
speaker connector and a good ground. There should The ohmmeter test lead connections for each test
be continuity. I f OK, go to Step 7. I f not OK, repair are shown in Antenna Tests (Fig. 1).
the open circuit as required.
(7) Install the radio. Connect the battery negative NOTE: This model has a two-piece antenna cable.
cable. Turn the radio on. Check for battery voltage at Tests 2 and 4 must be conducted in two steps to
the amplified speaker (+) circuit cavity of the speaker isolate a coaxial cable problem; from the coaxial
connector. I f OK, replace the faulty speaker. I f not cable connection under the right end of the instru
OK, repair the open circuit to the filter choke/ ment panel near the right cowl side panel to the
speaker relay as required. antenna base, and then from the coaxial cable con
nection to the radio chassis connection.
FILTER CHOKE/SPEAKER RELAY
The filter choke/speaker relay Is used to switch -o o-
power to the Individual speaker amplifiers used with 2
the Infinity premium speaker package. The choke
and relay are serviced only as a unit. I f the coaxial
speakers lack bass or low frequency response, while
no sound is noted at the woofers, the choke/relay is
suspect. However, before replacement make the fol
lowing checks of the choke/relay circuits. For circuit
descriptions and diagrams, refer to 8W-47 - Audio
System in Group 8W - Wiring Diagrams.
(1) Check the fuse in the fuseblock module. I f OK,
go to Step 2. I f not OK, replace the faulty fuse.
(2) Check for battery voltage at the fuse in the
fuseblock module. I f OK, go to Step 3. I f not OK,
(3) Unplug the choke/relay harness connector.
Check for battery voltage at the fused B(+) circuit
4
cavity of the choke/relay connector. I f OK, go to Step -o o~
4. I f not OK, repair the open circuit as required. J898F-7
(4) Probe the ground circuit cavity of the choke/re
lay connector. Check for continuity to a good ground. Fig. 1 Antenna Tests
There should be continuity. I f OK, go to Step 5. I f not TEST 1
OK, repair the open circuit to ground as required. Test 1 determines i f the antenna mast is insulated
(5) Turn the ignition switch to the On position and from the base. Proceed as follows:
turn the radio on. Check for battery voltage at the (1) Disconnect the antenna cable lead from the
radio 12-volt output circuit cavity of the choke/relay radio chassis and isolate.
connector. I f OK, go to Step 6. I f not OK, repair the (2) Connect one ohmmeter lead to the tip of the
open circuit as required. antenna mast and the other lead to the antenna
(6) Turn the radio and ignition switches to the Off base. Check for continuity.
position. Connect the choke/relay connector. Check
8F - 6 AUDIO SYSTEMS

(3) There should be no continuity. I f continuity Is Clean, tighten or repair the connections as
found, replace the faulty or damaged antenna base required.
and cable assembly. Also inspect the following secondary ignition sys
tem components:
TEST 2 • Spark plug wire routing and condition
Test 2 checks the antenna for an open circuit as • Distributor cap and rotor
follows: • Ignition coil
(1) Disconnect the antenna cable lead from the • Spark plugs.
radio chassis. Reroute the spark plug wires or replace the faulty
(2) Connect one ohmmeter test lead to the tip of components as required.
the antenna mast. Connect the remaining lead to the
tip of the antenna cable lead (the part inserted into
the radio). REMOVAL AND INSTALLATION
(3) Continuity should exist (the ohmmeter should
only register a fraction of an ohm). High or infinite RADIO
resistance indicates damage to the base and cable (1) Disconnect and isolate the battery negative
assembly. Replace the faulty base and cable, i f cable.
required. (2) Open the cup holder and remove the two
screws securing the assembly to the instrument
TEST 3 panel (Fig. 2). Remove the cup holder assembly from
Test 3 checks the condition of the vehicle body the instrument panel.
ground connection. This test should be performed
with the battery positive cable removed from the bat
tery. Disconnect both battery cables, the negative
cable first. Reconnect the negative cable and perform
the test as follows:
(1) Connect one ohmmeter test lead to the vehicle
fender and the other lead to the battery negative
post.
(2) The resistance should be less than one ohm.
(3) I f the resistance is more than one ohm, check
the braided ground strap connected to the engine and
the vehicle body for being loose, corroded, or dam
Fig. 2 Cup Holder Remove/Install
aged. Repair the ground strap connection, if required.
(3) Remove the ash receiver. Remove the two
TEST 4 screws securing the ash receiver bracket to the
Test 4 checks the condition of the ground between instrument panel (Fig. 3). Remove the ash receiver
the antenna base and the vehicle body as follows: bracket assembly from the instrument panel.
(1) Connect one ohmmeter test lead to the fender
and the other lead to the crimp on the coaxial
antenna cable shield.
(2) The resistance should be less then one ohm.
(3) I f the resistance is more then one ohm, clean
and/or tighten antenna base to fender mounting
hardware.
RADIO FREQUENCY INTERFERENCE

Inspect the ground connections at the following:
• Blower motor . J948E-9
• Electric fuel pump
• Generator Fig. 3 Ash Receiver Remove/Install
• Ignition module
• Wiper motor
• Antenna coaxial ground
• Radio ground
• Body-to-engine braided ground strap (if equipped).
i
BR AUDIO SYSTEMS 8F - 7
R E M O V A L AND I N S T A L L A T I O N ( C o n t i n u e d )
(4) Carefully pry the bezel away from the instru- ^ || \\
ment panel to disengage the retaining clips (Fig. 4).
J948F-5
Fig. 6 Radio Mounting

J948E-46
Fig. 4 duster Bezel Remove/install

(5) Unplug the connector from cigar lighter (Fig.
5).
, ELECTRICAL
CONNECTOR
CLIPS
ANTENNA
J948F-6
Fig. 7 Radio Connectors

(2) Remove the two screws in the door pull cup
and remove the cup (Fig. 8).
J948E-10
REMOVE 2 SCREWS
Fig, 5 Cigar Lighter Remove/Install
(6) Unplug the connector from the auxiliary power
outlet.
(7) Remove the 'two radio mounting screws from
the front of the radio (Fig. 6).
(8) Pull the radio out from the instrument panel
far enough to disconnect the wiring and the antenna
coaxial cable (Fig. 7).
(9) Remove the screw from the radio ground strap J948S-2
and remove the radio.
(10) Reverse the removal procedures to install. Fig. 8 Door Puil Cup Remove/install
(3) I f equipped, remove the manual window regu
SPEAKERS lator crank handle with a removal tool (Fig. 9).
(4) I f equipped, remove the power window and lock
FRONT DOOR
switches by reaching through the door pull cup open
ing and depressing the switch bezel rear retaining
cable.
tab (Fig. 10).
8F - 8 AUDIO SYSTEMS BR
DOOR HANDLE knob rearward to remove i t from the switch stem
REMOVAL TOOL (Fig. 12).
Fig, 9 Window Regulator Crank Handle Remove -

Typical
Fig. 12 Power Mirror Switch Knob Remove/Install
(8) Remove the mirror switch retaining nut from
the switch (Fig. 13).
Fig. 10 Switch Bezel Rear Retaining Tab

(5) Pull the rear of the switch bezel up and away
from the door trim panel.
(6) Unplug the wiring connectors from the
switches (Fig. 11).
Fig. 13 Power Mirror Switch Nut

(9) Using a wide flat-bladed tool such as a trim
stick, pry the trim panel away from the door around
the perimeter and remove the trim panel.
TABS FRONT CLIP J948S-8 NOTE: To aid in the removal of the trim panel, start
at the bottom of the panel.
Fig. 11 Door Switch Connectors
(10) Remove the screws holding the speaker(s) to
(7) On the driver's side only, i f equipped with
the inner door panel (Fig. 14).
power mirrors, pull the power mirror switch control
(11) Disconnect the speaker wiring connector and
remove the speaker.
BR — — — AUDIO SYSTEMS 8F - 9
Fig. 15 Knee Blocker Remove/Install
J948F-4
Fig. 14 Door Mounted Speaker Remove/instatl

REAM CAB SIDE PANEL

cable.
(2) Remove the rear cab side panel trim as
described in Group 23 - Body Components.
(3) Move the side panel trim far enough to access
the speaker mounting screws.
(4) Remove the speaker mounting screws.
(5) Pull the speaker out and unplug the wiring Fig. 16 RWAL Module Lower Mounting
connector.
FILTER CHOKE/SPEAKER RELAY

cable.
(2) Remove the five screws securing the knee
blocker to the lower instrument panel and remove
the knee blocker (Fig. 15).
(3) I f equipped, remove the two screws holding the
bottom of the RWAL module bracket to the instru
ment panel brace (Fig. 16).
(4) I f equipped, remove the screw holding the top
of the RWAL module bracket to the instrument panel
and remove the module (Fig. 17).
(5) Remove the two screws securing the relay/
choke mounting bracket to the instrument panel cen
ter support and remove the relay/choke assembly Fig. 17 RWAL Module Upper Mounting
(Fig. 18). ANTE11A
(6) Reverse the removal procedures to install. (1) Disconnect and isolate the battery negative
cable.
BR
PR517 A
CAP NUT
Fig. 18 Relay/Choke Assembly

(2) Remove the five screws holding the right cowl FRONT RIGHT FENDER
side kick panel/sill trim. Remove the kick panel/sill
trim.
(3) Remove the antenna mast from the antenna
body (Fig. 19),
ANTENNA
MAST
ANTENNA BODY
AND CABLE ASSEMBLY RN1008
928F-3
Fig. 21 Antenna Mounting - Typical
Fig. 19 Antenna Mast Remove/install engine compartment side of the dash panel outboard
(4) Remove the antenna cap nut using antenna of the powertrain control module, then through the
nut wrench (Special Tool C-4816) (Fig. 20). opening i n the cowl side reinforcement.
(5) Lower the antenna assembly through the (7) To install the antenna body and cable, route
fender far enough to gain access to the antenna body the coaxial cable between the fender and the cowl
(Fig. 21). side reinforcement to the engine compartment.
(6) Remove the antenna body and cable by pulling (8) Reverse the remaining removal procedures to
the coaxial cable and grommet out through the complete the installation. Tighten the antenna cap
nut to 7.9 N-m (70 in. lbs.).
BR HORN SYSTEMS 8G - 1
HORN SYSTEMS
CONTENTS
page page
GENERAL INFORMATION HORN SWITCH 2

INTRODUCTION 1 HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION
HORN RELAY . -1 HORN RELAY 3
HORN SWITCH 1 HORN SWITCH 3
HORN 1 HORN 4
HORN RELAY 1
GENERAL INFORMATION horn relay. The steering wheel and steering column
must be properly grounded for the horn switches to
INTRODUCTION function. The horn switches are serviced only as a set
Following are general descriptions of the major with their wiring. I f either switch should fail, both
components in the factory-installed horn systems. switches must be replaced.
Refer to 8W-41 - Horns/Cigar Lighter in Group 8W -
Wiring Diagrams for complete circuit descriptions HORN
and diagrams. The standard single, low-note, diaphragm-type
horn is located on a bracket behind the left end of
the front bumper. I t is grounded through its wiring
DESCRIPTION AND OPERATION connector and circuit to an eyelet near the power dis
tribution center, and receives battery feed through
HORN RELAY the closed contacts of the horn relay. I f the vehicle is
The horn relay is a International Standards Orga equipped with a dual horn option, a high-note, dia
nization (ISO) micro-relay. The terminal designations phragm-type horn is connected in parallel with, and
and functions are the same as a conventional ISO mounted next to, the standard low-note horn behind
relay. However, the micro-relay terminal orientation the front bumper.
(or footprint) is different, current capacity is lower,
and the relay case dimensions are smaller than on
the conventional ISO relay. DIAGNOSIS AND TESTING
The horn relay is a electro-mechanical device that
switches current to the horn when the horn switch HORN RELAY
on the steering wheel is depressed. See the Diagnosis For circuit descriptions * and diagrams, refer to
and Testing section of this group for more informa 8W-41 - Horns/Cigar Lighter in Group 8W - Wiring
tion on the horn relay's operation. Diagrams.
The horn relay is located in the Power Distribution
Center (PDC) in the engine compartment. Refer to RELAY TESTS
the PDC label for horn relay identification and loca The horn relay is located in the Power Distribution
tion. Center (PDC) in the engine compartment. Refer to
If a problem is encountered with a continuously the PDC label for horn relay identification and loca
sounding horn, i t can usually be quickly resolved by tion.
removing the horn relay from the PDC until further Remove the horn relay from the PDC as described
diagnosis is completed. in this group to perform the following tests:
(1) A relay in the de-energized position should
HORN SWITCH have continuity between terminals 87A and 30, and
Two horn switches are installed in the steering no continuity between terminals 87 and 30. I f OK, go
wheel, one on each side of the center-mounted driv to Step 2. I f not OK, replace the faulty relay.
er's airbag module. When either switch is depressed
it completes a circuit to ground for the coil side of the
8G - 2 HORN SYSTEMS BR

(2) Resistance between terminals 85 and 86 (elec HORN SWITCH
tromagnet) should be 75 ±5 ohms. I f OK, go to Step For circuit descriptions and diagrams, refer to
3. I f not OK, replace the faulty relay. 8W-41 - Horns/Cigar Lighter in Group 8W - Wiring
(3) Connect a battery to terminals 85 and 86. Diagrams.
There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A WARNING: ON ¥EHICLES EQUIPPED WITH AN AIR-
and 30. I f OK, see the Relay Circuit Test in this BAG, REFER TO GROUP 8M - PASSIVE RESTRAINT
group. I f not OK, replace the faulty relay. SYSTEMS BEFORE ATTEMPTING STEERING
WHEEL COMPONENT DIAGNOSIS OR SERVICE.
FAILURE TO TAKE THE PROPER PRECAUTIONS
MENT AND POSSIBLE PERSONAL INJURY.

cable. Remove the knee blocker. Check for continuity
between the metal steering column jacket and a good
TERMINAL L E G E N D ground. There should be continuity. I f OK, go to Step
NUMBER IDENTIFICATION
2. I f not OK, refer to Group 19 - Steering and check
30 COMMON FEED for proper installation of the steering column ground
85 COIL G R O U N D clip.
86 C O I L BATTERY (2) Remove the horn relay from the PDC. Unplug
87 NORMALLY OPEN
the horn switch wire connector. Check for continuity
87A NORMALLY CLOSED
between the steering column half of the horn switch
9514-16 wire connector and a good ground. There should be
no continuity. I f OK, go to Step 3. I f not OK, repair
Horn Relay the short circuit as required.
RELAY CIRCUIT TESTS (3) Check for continuity between the steering col
(1) The relay common feed terminal cavity (30) is umn half of the horn switch wire connector and the
connected to battery voltage and should be hot at all horn relay control circuit cavity in the PDC. There
times. I f OK, go to Step 2. I f not OK, repair the open should be continuity. I f OK, go to Step 4. I f not OK,
circuit to the PDC fuse as required. repair the open circuit as required.
(2) The relay normally closed terminal (87A) is (4) Check for continuity between the horn switch
connected to terminal 30 in the de-energized position, half of the horn switch wire connector and a good
but is not used for this application. Go to Step 3. ground. There should be no continuity. I f OK, go to
(3) The relay normally open terminal (87) is con Step 5. I f not OK, replace the faulty horn switches.
nected to the common feed terminal (30) in the ener (5) Depress one horn switch and check for continu
gized position. This terminal supplies battery voltage ity between the horn switch half of the horn switch
to the horn(s). There should be continuity between wire connector and a good ground. There should be
the cavity for relay terminal 87 and the horn(s) feed continuity. Repeat this test for the other horn switch.
terminal(s) at all times. I f OK, go to Step 4. I f not If either switch is not OK, replace the faulty horn
OK, repair the open circuit to the horn(s) as switches.
required.
(4) The coil battery terminal (86) is connected to HORN
the electromagnet in the relay. I t is connected to bat For circuit descriptions and diagrams, refer to
tery voltage and should be hot at all times. Check for 8W-41 - Horns/Cigar Lighter i n Group 8W - Wiring
battery voltage at the cavity for relay terminal 86. I f Diagrams.
OK, go to Step 5. I f not OK, repair the open circuit to (1) Disconnect the horn wiring connector. Measure
the PDC fuse as required. the resistance between the ground circuit cavity of
(5) The coil ground terminal (85) is connected to the horn connector and a good ground. There should
the electromagnet in the relay. I t is grounded be zero ohms resistance. I f OK, go to Step 2. I f not
through the horn switch when the horn switch is OK, repair the faulty horn ground circuit as
depressed. Check for continuity to ground at the cav required.
ity for relay terminal 85. There should be continuity (2) Depress the horn switch. There should be bat
with the horn switch depressed, and no continuity tery voltage at the horn relay output circuit cavity of
with the horn switch released. I f not OK, see the the horn connector. I f OK, replace the faulty horn. I f
diagnosis for the Horn Switch in this group. not OK, repair the open circuit to the horn relay as
required.
BR HORN SYSTEMS 8G - 3
REMOVAL AND INSTALLATION SPEED CONTROL

SWITCHES
HORN RELAY
(1) Disconnect and isolate the battery negative cable.
(2) Remove the cover from the Power Distribution
POWER
DISTRIBUTION
CENTER
(PDC)
. ,f REMOVE 2 SCREWS i | K J948H-9
Fig. 2 Speed Control Switch/Trim Bar Remove/Install
J9414-10

(3) Refer to the label on the PDC for horn relay
identification and location.
(4) Remove the horn relay by unplugging i t from
the PDC.
(5) Install the horn relay by aligning the relay ter
minals with the cavities in the PDC and pushing the
relay firmly into place. SPEED CONTROL
SWITCHES J948H-8
(6) Install the PDC cover.
(7) Connect battery negative cable. Fig. 3 Speed Control Switch Connector Remove/Install
(8) Test the relay operation.
H O i i SWITCH
WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG,

REFER TO GROUP 8 1 - PASSIVE RESTRAINT SYSTEMS
BEFORE ATTEMPTING STEERING WHEEL OR STEERING
COLUMN COMPONENT DIAGNOSIS OR SERVICE. FAIL
URE TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND
POSSIBLE PERSONAL INJURY.

cable. Wait two minutes for the airbag system capac
itor to discharge before further service.
(2) From the underside of the steering wheel,
remove the speed control switch or trim bar mount
ing screws (Fig. 2).
(3) Pull the switch/trim bar from the steering
wheel and unplug the wiring connector (Fig. 3).
(4) Remove the four nuts attaching the airbag J948G-2
module to the steering wheel (Fig. 4).
Fig. 4 Airbag Module Remove/Install
86 - 4 HORN SYSTEMS
R E M O V A L A N D INSTALLATION fContinued)
(5) Remove the airbag module from the steering (7) Disconnect the horn" switch wire connectors and
wheel. remove the horn switch assembly (Fig. 7).
(6) Using a small screwdriver pry the horn button
from the steering wheel spoke (Fig. 5). There are two
locking tabs holding each horn button to the steering
wheel spoke cavities (Fig. 6).
Fig. 7 Horn Switch Connectors

Tighten the airbag module mounting nuts to 1.5 N-m
(15 in. lbs.).
HORN
cable.
(3) Disconnect the horn(s) wiring connector(s) (Fig.
8).
Fig. 8 Horn Remove/install

(4) Remove the bolt holding the horn bracket to
the bumper support and remove the horn(s).
Tighten the horn bracket mounting bolt to 28 N-m
Fig. 6 Horn Sutton Locking Tabs
(20 ft. lbs.).
BR VEHICLE SPEED CONTROL SYSTEM 8H -1
V E H I C L E S P E E D CONTROL S Y S T E M
CONTENTS
page page
GENERAL INFORMATION SPEED CONTROL SERVO 8

INTRODUCTION 1 SPEED CONTROL SWITCH 7
DESCRIPTION AND OPERATION STOP LAMP SWITCH 8
POWERTRAIN CONTROL MODULE 2 VACUUM SUPPLY TEST 8
SERVO CABLE 2 VEHICLE SPEED SENSOR 7
SPEED CONTROL SERVO 1 REMOVAL AND INSTALLATION
SPEED CONTROL SWITCH 1 POWERTRAIN CONTROL MODULE 11
STOP LAMP SWITCH 1 SERVO CABLE 11
VACUUM RESERVOIR 2 SPEED CONTROL SERVO 9
VEHICLE SPEED SENSOR 2 SPEED CONTROL SWITCH 11
DIAGNOSIS AND TESTING STOP LAMP SWITCH 11
ON-BOARD DIAGNOSTICS TEST 2 VACUUM RESERVOIR 13
POWERTRAIN CONTROL MODULE (PCM) . . . . 9 VEHICLE SPEED SENSOR 13
ROAD TEST 2 SPECIFICATIONS
SPEED CONTROL ELECTRICAL TEST 7 TORQUE SPECIFICATIONS 13
G E N E R A L INFORMATION porting six different speed control functions are used.

The outputs from these switches are filtered into one
INTRODUCTION input. The Powertrain Control Module (PCM) deter
The vehicle speed control system is electronically mines which output has been applied through resis
controlled and vacuum operated. The system is tive multiplexing. The input circuit voltage is
designed to operate between approximately 35 and measured by the PCM to determine which switch
85 mph (56 and 137 km/h). Following are general function has been selected.
descriptions of the major components in the speed An indicator lamp (LED) located on the switch
control system. Refer to Group 8W, Wiring Diagrams module is energized by the PCM. This occurs when
for complete circuit descriptions and wiring dia the speed control system has been engaged.
grams. The three switches are labeled: OFF/ON,
RESUME/ACCEL, SET/DECEL. Refer to the owner's
manual for more information on speed control switch
BESeHIPYlOfl AND OPERATION functions and setting procedures. The individual
switches cannot be repaired. I f one individual switch
SPEED CONTROL SERVO fails, or the indicator lamp fails, the entire switch
The speed control servo is mounted to a bracket module must be replaced.
under the battery tray on the left side of engine com
partment. The servo unit consists of a solenoid valve STOP LAMP SWITCH
body, a vacuum servo and the mounting bracket. The Vehicles equipped with the speed control option use
PCM controls the solenoid valve body. The solenoid a dual function stop lamp switch. The switch is
valve body controls the application and release of mounted in the same location as the conventional
vacuum to the diaphragm of the vacuum servo. The stop lamp switch, on the brake pedal mounting
servo unit cannot be repaired and is serviced only as bracket under the instrument panel. The PCM mon
a complete assembly. itors the state of the dual function stop lamp switch.
Refer to Group 5, Brakes for more information on
SPEED CONTROL SWITCH stop lamp switch service and adjustment procedures.
The speed control switch module is mounted to the
center of the steering wheel below the driver's airbag
module. Three momentary contact switches, sup-
8H - 2 VEHICLE SPEED CONTROL SYSTEM BR
SERVO CAILE be corrected before proceeding. Refer to Group 8E,
The speed control servo cable is connected between Instrument Panel and Gauges for speedometer diag
the speed control vacuum servo diaphragm and the nosis.
throttle body control linkage. This cable causes the I f a road test verifies a system problem and the
throttle control linkage to open or close the throttle speedometer operates properly, check for:
valve In response to movement of the vacuum servo • A mis adjusted brake (stop) lamp switch. This
diaphragm. could also cause an intermittent problem.
• Loose or corroded electrical connections at the
POWERTRAIN CONTROL MODULE servo. Corrosion should be removed from electrical
The speed control electronic control circuitry is terminals and a light coating of Mopar Multipurpose
integrated Into the Powertrain Control Module Grease, or equivalent, applied.
(PCM). The PCM Is located In the right-rear area of • Loose or leaking vacuum hoses or connections.
the engine compartment. The PCM speed control • Secure attachment of both ends of the speed con
functions are monitored by the On-Board Diagnostics trol servo cable.
(OBD). All OBD-sensed systems are monitored by the • Smooth operation of throttle linkage and throttle
PCM. Each monitored circuit is assigned a Diagnos body air valve.
tic Trouble Code (DTC). The PCM will store a DTC in
electronic memory for certain failures it detects. See CAUTION: When test probing for voltage or conti
On-Board Diagnostic Tests in this group for more nuity at electrical connectors, care must be taken
information. The PCM cannot be repaired and must not to damage connector, terminals or seals. If
be replaced i f faulty. these components are damaged, intermittent or
complete system failure may occur.
VACUUM RESERVOIR
The vacuum reservoir is mounted under the cowl
ON-BOARD DIAGNOSTICS TEST
intake air screen in the cowl plenum. The reservoir
The Powertrain Control Module (PCM) monitors
contains a one-way check valve to trap engine vac
critical input and output circuits of the speed control
uum in the reservoir. When engine vacuum drops, as
system making sure they are operational. A Diagnos
in climbing a grade while driving, the reservoir sup
tic Trouble Code (DTC) is assigned to each input and
plies the vacuum needed to maintain proper speed
output circuit monitored by the On-Board Diagnostic
control operation. The vacuum reservoir cannot' be
(OBD) system. Some circuits are checked continu
repaired and must be replaced i f faulty.
ously and some are checked only under certain con
ditions.
VEHICLE SPEED SENSOR
I f the OBD system senses that a monitored circuit
The Vehicle Speed Sensor (VSS) is a' pulse genera
is bad, i t will put a DTC into electronic memory. The
tor mounted to an adapter near the transmission out
DTC will stay in electronic memory as long as the
put shaft. The sensor Is driven through the adapter
circuit continues to be bad. The PCM is programmed
by a speedometer pinion gear. The VSS pulse signal
to clear the memory after 50 engine starts i f the
to the speedometer/odometer is monitored by the
problem does not occur again.
PCM speed control circuitry to determine vehicle
speed and to maintain speed control set speed. Refer DIAGNOSTIC TROUBLE CODES
to the appropriate Powertrain Diagnostic Procedures Diagnostic Trouble Codes (DTCs) are two-digit
manual for diagnosis and testing of this component. numbers flashed on the Malfunction Indicator (Check
Refer to Group 14, Fuel System for removal/installa Engine) Lamp that identify which circuit is bad. A
tion procedures. DTC description can also be read using the DRB scan
tool. Refer to Group 25, Emission Control System for
DIAGNOSIS AND TESTING more DTC information.
A DTC does not identify which component in a cir
ROAD TEST cuit is bad. Thus, a DTC should be treated as a
symptom, not as the cause for the problem. In some
Perform a vehicle road test to verify reports of
cases, because of the design of the diagnostic test
speed control system malfunction. The road test
procedure, a DTC can be the reason for another DTC
should include attention to the speedometer. Speed
to be set. Therefore, i t is important that the test pro
ometer operation should be smooth and without flut
cedures be followed in sequence, to understand what
ter at all speeds.
caused a DTC to be set.
Flutter i n the speedometer indicates a problem
Refer to the following Speed Control Diagnostic
which might cause surging in the speed control sys
Trouble Code chart for DTCs which apply to the
tem. The cause of any speedometer problems should
BR VEHICLE SPEED CONTROL SYSTEM 8H - 3

warning: T H E U S E O P T H E SPEED c O N T R O L start engine
is not R E C O M M E N D E D W H E N D R I V I N G
C O N D I T I O N S D O N O T PERMIT M A I N T A I N I N G
A C O N S T A N T SPEED, S U C H A S H E A V Y
TRAFFIC O RO N THAT
I C Y .SNOWCOVEREDORSLIPPERY speed control
ACCELERATE VEHICLE
E N G A G E S WHEN
T O DESIRED SPEED
engine IS STARTED
PUSH O N BUTTON FAULTY

TO "ON" POSITION. ELECTRICAL CIRCUIT*
\ DEFECTIVE SERVO
SPEED CONTROL ENGAGES
PUSH AND RELEASE
WITHOUT PUSHING THE
"SET/COAST" BUTTON
"SET/COAST" BUTTON
FAULTY ELECTRICAL CIRCUIT* REMOVE FOOT FROM

ACCELERATOR. SPEED
SHOULD BE CONTROLLED
DEFECTIVE SERVO
r
NO SPEED CONTROL WHEN HIJIIflfiG StJiGE O R mcMmm S A G SPEED S E T T I N G ACTii
SET/COAST BUTTON IS VARIATIONS ONHK1SOR LOCK-IN, T O O HIGH
PRESSED AND RELEASED A T L O W SPIIDS i TRARJR IOWMIG OR mo mm
TORQUE CONVERTER
ZZZEII:: zzuzzz
ENGINE
FUSE BLOWN CLUTCH V A C U U M LEAK
PERFORMANCE
ROUGHNESS
X
AMPLIFICATION
NO VACUUM AT O F ENGINE VACUUM DEFECTIVE SERVO
SERVO SURGE LEAK
SPEED CONTRQt
_ t " I
EXCESSIVE LOAD M A Y
n:.zizr.z
DEFECTIVE
THROTTLE CABLE DEFECTIVE SERVO REQUIRE MANUAL
CABLE
DISCONNECTED ASSISTANCE O N HILLS
ZZZHZZH
DEFECTIVE V A C U U M
IMPROPER STOP LAMP DEFECTIVE DEFECTIVE
RESERVO!R
SWITCH ADJUSTMENT CABLE V A C U U M RESERVOIR
(CHECK VALVE)
DEFECTIVE
FAULTY ELECTRICAL
POWERTRAIN
CIRCUIT*
CONTROL MODULE
A N D ADJUSTMENTS ARE
DEFECTIVE SERVO iTE S E C T I O N O P
MANUAL.
^ ^ ^ ^
DEFECTIVE V A C U U M
RESERVOIR
J938H-8
DIAGNOSIS CHART 1—GAS ENGINE
»H - 4 VEHICLE SPEED CONTROL SYSTEM BR
DRIVE VEHICLE O V E R
R O U G H ROADS
I
UNIT DISENGAGES
1
TAP BRAKE PEDAL
LIGHTLY, SPEED
ON ROUGH ROADS C O N T R O L SHOULD
I
IMPROPER
DISENGAGE
NO SYSTEM
ADJUSTMENT OF STOP DISENGAGEMENT
LAMP A N D SPEED SPEED C O N T R O L WHEN SHAKE PEDAL
C O N T R O L SWITCH* DIESENGAGES IS DEPRESSED
I
FAULTY
ELECTRICAL
CIRCUIT
I
PUSH RESUME/ACCEL
SWITCH VEHICLE
DEFECTIVE OR
IMPROPERLY ADJUSTED
STOP LAMP A N D
SPEED C O N T R O L
SWITCH
S H O U L D RESUME
PREVIOUSLY
MEMORIZED S P E E D
I
SPEED C O N T R O L
ENGIN1 DOES
THROTTLE CABLE
mm RETURN TO
KINKED OR DAMAGED
NORMAL IDLE
VEHICLE RESUMES
SPEED
I
I
FAULTY ELECTRICAL
SPEED C O N T R O L
THROTTLE CABLE CIRCUIT*
KINKED OR DAMAGED
i
DEPRESS BRAKE
PEDAL, S P E E D
CONTROL
I
DEFECTIVE S E R V O
STANDARD THROTTLE SHOULD DISENGAGE
LINKAGE FAULTS
SPEED C O N T R O L N O SYSTEM
1
RESUME SPEED
DISENGAGES DISENGAGE IS POSSIBLE
W H E N BRAKE PEDAL IS BELOW 2 0 M.P.H.
NO RESUME WHEN DEPRESSED
BUTTON IS PRESSED
T
I DEFECTIVE BRAKE
SWITCH
DEFECTIVE VEHICLE
SPEED SENSOR
DEFECTIVE SWITCH
± t
I
FAULTY ELECTRICAL SPIED CONTROL
FAULTY ELECTRICAL
CIRCUIT*
DEFECTIVE
E N G I N E CONTROLLER
CIRCUIT* SYSTEM OK
DEFECTIVE POWERTRAIN
CONTROL MODULE J948H-21
DIAGNOSIS CHART 2—GAS ENGINE
BR — — VEHICLE SPEED CONTROL SYSTEM 8H - 5
WAiNlMGs m i USE O F m i SPEED C O N T R O L

START ENGINE
is N O T RECOMMENDED W H I N MM N O
COfJDfTONS D O NOT PERMIT MAINTAINING
A CONSTANT SPEED, SUCH AS H I A W
TftATOC O R O N mm% THAT A H WINDING, SPUD C O N T R O L
ACCELERATE VEHICLE
KY SHOW C O V B K D Oft SUPPERY.
# ENGAGES WHEN
TO DESIRED SPEED E N G I N E IS STARTED
PUSH ON/CRUISE
FAULTY
BUTTON TO "ON"
POSITION ELECTRICAL CIRCUIT*
1
SPEED CONTROL DEFECTIVE SERVO
ENGAGES WITHOUT PUSH AND RELEASE
PUSHING THE "SET/DECEL" BUTTON
"SET/DECEL" BUTTON
FAULTY ELECTRICAL CIRCUIT* REMOVE FOOT FROM

ACCELERATOR. SPEED
SHOULD BE CONTROLLED
DEFECTIVE SERVO
N O SPEED CONTROL HUNTING SURGE OR EXCESSIVE SAG >SEflN6AFra

WMm SB/MSB. BUTTON SKID VARIATION ON H1US m ijOOCmTOOIfGH
IS PRESSED AND REUA5ED AflOW M f i A I U i TOWIN© OftTOOUOW
?
TORQUE CONVERTER ENGINE "INSUFFICIENT
FUSE BLOWN
CLUTCH ROUGHNESS PERFORMANCE VACUUM AT SERVO
"INSUFFICIENT AMPLIFICATION OF "INSUFFICIENT

DEFECTIVE SERVO
VACUUM AT SERVO ENGINE SURGE VACUUM AT SERVO
T
SPEED CONTROL EXCESSIVE LOAD MAY
THROTTLE CABLE DEFECTIVE SERVO REQUIRE MANUAL DEFECTIVE CABLE
DISCONNECTED ASSISTANCE ON HILLS
t
IMPROPER STOP LAMP "REFER T O G R O U P 5 - BRAKES
DEFECTIVE CABLE
SWITCH ADJUSTMENT FOR V A C U U M PUMP DIAGNOSIS.
FAULTY ELECTRICAL DEFECTIVE

POWERTRAIN
CIRCUIT* CONTROL MODULE
*TEST AMP mswmmms AH

DEFECTIVE SERVO m mmMmmmm wmmm m
DEFECTIVE ENGINE
SPEED SENSOR
J948H-28
DIAGNOSIS CHART 1—DIESEL ENGINE
DRIVE VEHICLE OVER

ROUGH ROAD
TAP BRAKE PEDAL

UNIT DISENGAGES LIGHTLY, SPEED
omwommmm CONTROL SHOULD
DISENGAGE
IMPROPER
ADJUSTMENT OF SPEED CONTROL
STOP LAMP SWITCH* DISENGAGES
FAULTY
ELECTRICAL
CIRCUIT
DEFECTIVE OR
IMPROPERLY ADJUSTED
STOP LAMP SWITCH
PUSH RESUME/ACCEL
SWITCH VEHICLE
SHOULD RESUME
PREVIOUSLY
SPEED CONTROL
MEMORIZED SPEED
THROTTLE CABLE
NomEfURNio KINKED OR DAMAGED
NORMAL t o i l
VEHICLE RESUMES FAULTY ELECTRICAL

SPEED CONTROL CIRCUIT*
THROTTLE CABLE SPEED
KINKED OR DAMAGED
DEPRESS BRAKE
DEFECTIVE SERVO
PEDAL, SPEED
STANDARD THROTTLE
CONTROL
LINKAGE FAULTS
SHOULD DISENGAGE
N O SYSTEM ESPEEI
WO USUI I E WHEN SPEED CONTROL
B U T T O N m>K33S8aS> j DISENGAGES
DISENGAGE m
WHEN BRAKE PEDAL IS BELOW 2
DEPRESSED
r
DEFECTIVE SWITCH DEFECTIVE DEFECTIVE VEHICLE

POWERTRAIN SPEED SENSOR
CONTROL MODULE
f
DEFECTIVE
FAULTY ELECTRICAL
FAULTY ELECTRICAL
POWERTRAIN
CIRCUIT*
CIRCUIT*
CONTROL MODULE
f
STICKY BRAKE SWITCH J948H-27
DIAGNOSIS CHART 2—DIESEL ENGINE


speed control system. Refer to the appropriate Pow described within the tests on the following pages.
ertrain Diagnostic Procedures manual to diagnose an Refer to Group 8W, Wiring Diagrams for speed con
on-board diagnostic system trouble code. trol electrical schematics and connector location.
RETRIEVING DIAGNOSTIC TROUBLE CODES CAUTION: When test probing for voltage or conti
To start this function, cycle the ignition switch ON- nuity at electrical connectors, care must be taken
OFF-ON-OFF-ON within 5 seconds. This will cause not to damage connector, terminals or seals. If
any DTC stored in the PCM memory to be displayed. these components are damaged, intermittent or
The instrument panel mounted malfunction indicator complete system failure may occur.
(Check Engine) lamp will display a DTC by flashing
on and off. There is a short pause between flashes When electrical connections are removed, corrosion
and a longer pause between digits. A l l DTCs dis should be removed from electrical terminals and a
played are two-digit numbers, with an approximate light coating of Mopar Multi-Purpose Grease, or
four-second pause between codes. equivalent, should be applied.
An example of a DTC is as follows: Inspect connectors for damaged terminals. A poor
(1) Lamp on for 2 seconds, then turns off. electrical connection can cause a complete or intermit
(2) Lamp flashes 1 time pauses and then flashes 5 tent malfunction. For this reason, a poor connection
times. may be misdiagnosed as a component malfunction.
(3) Lamp pauses for 4 seconds, flashes 3 times,
pauses, then flashes 4 times. VEHICLE SPEED SENSOR
The two DTCs are 15 and 34. Any number of For diagnosis and testing of the speed sensor, refer
DTCs can be displayed, as long, as they are in mem to the appropriate Powertrain Diagnostic Procedures
ory. The lamp will flash until all stored DTCs are service manual.
displayed. A DTC code number 55 signifies the end of
tests. SPEED CONTROL SWITCH
I f a DTC number 15 or 34 is observed, refer to the For complete speed control system diagnosis, refer
appropriate Powertrain Diagnostic Procedures man to the appropriate Powertrain Diagnostic Procedures
ual. Correct any problems found in your diagnosis, manual. To test the speed control switch only, refer to
then recheck for a DTC after corrections are com the following:
pleted. Use the DRB scan tool to erase a DTC after
repair. WARNING: BEFORE ATTEMPTING TO DIAGNOSE,
REMOVE OR INSTALL ANY AIRBAG SYSTEM OR
SPEED CONTROL ELECTRICAL TEST RELATED STEERING WHEEL AND STEERING COL
Two different test methods may be used to check UMN COMPONENTS, YOU MUST FIRST DISCON
the electronic speed control system. One involves NECT AND ISOLATE THE BATTERY NEGATIVE
using the DRB scan tool. I f this test method is (GROUND) CABLE. WAIT 2 MINUTES FOR SYSTEM
desired, refer to the appropriate Powertrain Diagnos CAPACITOR TO DISCHARGE BEFORE FURTHER
tic Procedures service manual. SYSTEM SERVICE. FAILURE TO DO SO COULD
The other test method will involve the use of a RESULT IN ACCIDENTAL DEPLOYMENT AND POS
volt/ohm meter. The volt/ohm meter method is SIBLE PERSONAL INJURY.
SPEED CONTROL DIAGNOSTIC TROUBLE CODES
Diagnostic Trouble
DRB Scan Tool Display Description of Diagnostic Trouble Code
Code
No vehicle distance (speed) sensor signal
15** No Vehicle Speed Sensor Signal
detected during road load conditions.
An open or shorted condition detected in the
34* Speed Control Solenoid Circuits Speed Control vacuum or vent solenoid
circuits.
Completion of fault code display on Check
55* N/A
Engine Lamp.
* Check Engine Lamp will not illuminate at all times if this Diagnostic Trouble Code was recorded. Cycle ignition key
as described in manual and observe code flashed by Check Engine Lamp.
** Check Engine Lamp will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
8H - 8 VEHICLE SPEED C O l T i O L SYSTEM BR
(1) Disconnect negative battery cable. Wait 2 min SPEED CONTROL SERVO
utes for airbag system capacitor to discharge. For complete speed control system diagnosis, refer
(2) Remove speed control switch module from to the appropriate Powertrain Diagnostic Procedures
steering wheel. Refer to the removal/installation sec manual. To test the speed control servo only, refer to
tion for procedures. the following:
(3) Check speed control switch module continuity The engine must be started and running for the
as shown in chart (Fig. 1). I f OK, reinstall switch. I f following voltage tests.
not OK, replace switch module assembly. The individ (1) Start engine.
ual switches and the indicator lamp can not be ser (2) Disconnect 4-way electrical connector at servo
viced separately. (Fig. 2).
(3) Turn speed control switch to ON position.
REAR VIEW OF SWITCH (4) Check for battery voltage at pin-3 of wiring
harness 4-way connector (Fig. 3). This is the 12 volt
o o o
feed from the stoplamp switch. When the brake pedal
PIN 1 PIN 2 n i , fl PIN 3
is depressed, voltage should not be present at pin-3.
I f voltage is not present with brake pedal not
depressed, check for continuity between servo and
SWITCH RESISTANCE RESISTANCE stop lamp switch. Also check stop lamp switch
POSITION BETWEEN BETWEEN adjustment. Refer to Group 5, Brakes for procedures.
PINS 2 AND 3 PINS 1 AND 2
(5) Connect a small gauge jumper wire between
the disconnected servo harness 4-way connector
NO S W I T C H E S OPEN 806 ohms pin-3, and pin-3 on the servo. Check for battery volt
DEPRESSED CIRCUIT +/- 8 ohms
age at pins-1, 2 and 4 of the servo. If battery voltage
is not at these pins, replace the servo.
909 ohms
ON
+/- 9 ohms
15,400 ohms
RESUME/ACCEL +/-154 ohms
6650 ohms
SET/COAST +/- 66 ohms
80468d39
Fig. 1 Speed Control Switch Continuity

STOP LAMP SWITCH
For continuity checks and switch adjustment, refer
to Group 5, Brakes.
VACUUM SUPPLY TEST

(1) Gain access to vacuum reservoir. Refer to
Removal/Installation section for procedures.
(2) Disconnect vacuum hose at the servo and
install a vacuum gauge into the disconnected hose.
(3) Start engine and observe gauge at idle. Vac
uum gauge should read at least ten inches of mer
cury.
(4) I f vacuum does not meet this requirement,
check for vacuum leaks or poor engine performance. Fig. 2 Speed Control Servo Location
On diesel powered engines, refer to Group 5, Brakes (6) Turn ignition switch to OFF position. Check for
for vacuum pump diagnosis. continuity between disconnected servo harness
PIN 2 PIN 3
EE
=
m PIN 1 PIN 4
CONNECTOR
SHOWN FROM
TERMINAL END
PIN 4 PIN 3 PIN 2 PIN 1
Fig. 3 Servo 4-Way Harness Connector

4-way connector pin-4 and a good ground. There
should be continuity. I f not OK, repair open circuit to - SERVO BRACKET
ground as required. SCREWS (3)
J948H-5
POWERTRAIN COITROL MODULE ( P C i )
For complete PCM diagnosis on the speed control Fig. 4 Servo Removat/lnstallation
system, refer to the DRB scan tool and the appropri (6) Connect electrical connector to servo terminals.
ate Powertrain Diagnostic Procedures manual.
S.OL ¥ - 1 0 AND S.BL DIESEL ENGINE—
REMOVAL
REMOVAL AND INSTALLATION (1) Disconnect both battery cables, negative cables
first.
SPEED CONTROL SERVO (2) Remove 2 bolts and battery holddown (Fig. 5).
V-6/V-8 GAS ENGINES—REMOVAL
(1) Disconnect vacuum hose at servo (Fig. 4).
(2) Disconnect electrical connector at servo.
(3) Remove 2 nuts from cable sleeve.
(4) Pull speed control cable away from servo to
expose cable hairpin clip. '
(5) Remove hairpin clip attaching cable to servo.
(6) Pull servo away from mounting bracket.
INSTALLATION
(1) Insert servo studs through holes i n servo
mounting bracket.
(2) With throttle blocked to full open position,
align hole in cable sleeve with hole in servo pin and
install hairpin clip. ^J948B-2
(3) Insert servo studs through holes i n cable
sleeve. Fig. 5 Battery Holddown
(4) Install 2 attaching nuts and tighten to 6 N-m (3) I f equipped, pull up on battery heat shield to
(50 in. lbs.) torque. remove i t (Fig. 6).
(5) Connect vacuum hose to servo.
REHOWAL A N D INSTALLATION (Continued)
Fig. 6 Battery Heat Shield Fig. 8 Battery Tray Mounting

(4) Remove battery from vehicle.
(5) From under left front wheel opening, remove 2
forward battery tray nuts (Fig. 7).
Fig. 9 Servo Mounting

(10) Pull speed control cable away from servo to
expose cable hairpin clip (Fig. 10).
Fig, 7 Forward Battery Tray Nuts (11) Remove hairpin clip attaching cable to servo.
(6) Remove 2 nuts and 2 bolts holding battery tray (12) Pull servo away from mounting bracket.
to vehicle (Fig. 8).
INSTALLATION
(7) Lift battery tray up far enough for access to
(1) Insert servo studs through holes in servo
speed control servo electrical connector (Fig. 9).
mounting bracket.
(8) Unplug electrical connector.
(9) Remove 2 nuts from cable sleeve.
B R — _ VEHICLE SPEED CONTROL SYSTEM 8H - 11
(2) From underside of steering wheel, remove 2
speed control switch mounting screws (Fig. 11).
CLOCKSPRING
Fig. 10 Servo Cable Hairpin Clip

(2) With throttle blocked to full open position,
align hole in cable sleeve with hole in servo pin and SWITCH 908M-1
install hairpin clip.

Fig. 11 Speed Control Switch Remove/Install
(3) Insert servo studs through holes in cable
sleeve. (3) Pull switch module assembly from wheel and
(4) Install 2 attaching nuts and tighten to 6 N-m unplug electrical connector.
(5) Connect vacuum hose to servo. INSTALLATION
(6) Connect electrical connector to servo terminals. (1) Plug electrical connector into switch module.
(7) Install battery tray. Tighten all battery tray (2) Install switch with 2 screws.
mounting hardware to 16 N-m (140 in. lbs.) torque. (3) Tighten screws to 1.5 N-m (15 in. lbs.) torque
(8) Install battery in vehicle making sure battery
is properly positioned on battery tray. STOP LAMP SWITCH
(9) I f equipped, install battery heat shield. Refer to Group 5, Brakes for removal/installation
(10) Install battery holddown clamp, making sure and adjustment procedures.
it is properly positioned on battery. Tighten bolt to 4
N-m (35 in. lbs.) torque. SERVO CABLE
REMOVAL/INSTALLATION
SPEED CONTROL SWITCH
(1) Remove air cleaner (all except V-10 and diesel
WARNING: B E F O R E ATTEMPTING TO DIAGNOSE, engine).
REMOVE OR INSTALL ANY AIRBAG SYSTEM OR (2) Using finger pressure only, remove speed con
RELATED STEERING W H E E L AND STEERING COL trol cable connector at bellcrank by pushing connec
UMN COMPONENTS YOU MUST FIRST DISCON tor off the bellcrank (Fig. 12), (Fig. 13) or (Fig. 14).
NECT AND ISOLATE THE BATTERY NEGATIVE DO NOT try to pull connector off perpendicular to
(GROUND) C A B L E . WAIT 2 MINUTES FOR SYSTEM the bellcrank.
CAPACITOR TO DISCHARGE B E F O R E FURTHER (3) Squeeze tabs on speed control cable and push
SYSTEM S E R V I C E . FAILURE TO DO S O COULD out of locking plate.
RESULT IN ACCIDENTAL DEPLOYMENT AND POS (4) Remove servo cable from servo as described in
S I B L E PERSONAL INJURY. Speed Control Servo Remove/Install.
(5) Reverse removal procedures to install.
REMOVAL POWERTRAIN CONTROL MODULE

(1) Disconnect and isolate negative battery cable For Removal/Installation refer to Group 14, Fuel
from battery. Injection System.
8H - 1 2 VEHICLE SPEED CONTROL SYSTEM BR
Fig. 13 Servo Cable—V-10 Engine

BR — VEHICLE SPEED CONTROL SYSTEM 8H - 1 3
Fig 14 Servo Cable—Diesel Engine

VACUUM RESERVOIR
L
mEmOWAL/mSTMLLMTIOm
(1) Lift wiper arm to permit the latch (Fig. 15) to
be pulled out to the holding position. Remove arms
from pivots using a rocking motion.
CAUTION: The use of a screwdriver or other pry
ing tool to remove a wiper arm may distort it. This
distortion could allow the arm to come off the pivot
J948K-3
shaft, regardless of how carefully it is installed.
Fig. 16 Cowl Screen Weatherstrip
(6) Disconnect all hoses.
UNLOCKED (7) Reverse removal procedures to install. Refer to
POSITION Group 8K, Wiper and Washer Systems for correct
indexing of wiper arms.
LOCKED
POSITION VEHICLE SPEED SENSOR
For Removal/Installation of the Vehicle Speed Sen
sor refer to Group 14, Fuel System.
J948K-21
Fig. 15 Removing Wiper Arms SPECIFICATIONS

(2) Remove weather-strip along front edge of cowl
TOROUE SPECIFICATIONS
screen (Fig. 16).
(3) Release plastic anchor screws (Fig. 17).
Description Torque
(4) Move cowl screen aside far enough to access
Servo Mounting Bracket Nuts. . .8.5 N-m (75 in. lbs.)
reservoir in right cowl plenum area.
Switch Module Mounting
(5) Remove 2 push nuts and slide vacuum reser
voir off studs (Fig. 18). Screws 1.5 N-m (15 in. lbs.)
BR TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J -1
TURN SIGNAL AND HAZARD WARNING SYSTEMS

CONTENTS
page page
GENERAL INFORMATION TURN SIGNAL SYSTEM 1

INTRODUCTION 1 iiAONOSIS AND TESTING!
DESCRIPTION AND OPERATION HAZARD WARNING SYSTEM 3
HAZARD WARNING FLASHER 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 2
HAZARD WARNING SYSTEM 1 MULTI-FUNCTION SWITCH 3
MULTI-FUNCTION SWITCH 2 TURN SIGNAL SYSTEM 2
TURN SIGNAL FLASHER 1 REiOWAL A N i INSTALLATION
TURN SIGNAL INDICATOR LAMPS 2 HAZARD WARNING/TURN SIGNAL FLASHER . . 4
TURN SIGNAL LAMPS 2 MULTI-FUNCTION SWITCH . . . . . . . . . . . . . . . . 5
G E N E R A L INFORMATION cators, front park/turn signal lamps and rear tail/

stop/turn signal lamps will flash.
INTRODUCTION
Following are general descriptions of the major TURN S l i N A L FLASHER
components in the turn signal and hazard warning The turn signal flasher contains one fixed contact
systems. Refer to 8W-52 - Turn Signals i n Group 8W point, and one contact point attached to a flexible
- Wiring Diagrams for complete circuit descriptions bimetal arm. The contact points are normally closed.
and diagrams. When . a turn signal is activated, current flows
through the flasher. As the current flows through the
bimetal arm, i t heats and flexes to pull the contact
DESCRIPTION AND OPERATION points open, stopping current flow. As the bimetal
arm cools, i t straightens until the contact points
TURN S l i N A L SYSTE1 close, then the cycle repeats.
With the ignition switch in the On or Accessory The standard turn signal flasher is designed to
position, and the multi-function switch control lever handle the current flow requirements of the factory-
moved up (right turn) or down (left turn), the turn installed lighting. I f supplemental lighting is added
signal system is activated. to the turn signal circuits, such as when towing a
When the turn signal system is activated, the trailer with lights, the current flow through the
selected (right or left) turn signal indicator lamp, flasher increases. This causes the flash rate to
front park/turn signal lamp and rear tail/stop/turn increase. I t is recommended that the standard
signal lamp bulbs will flash. flasher be replaced with a heavy-duty (hazard warn
ing) flasher when supplemental lighting is added.
HAZARi WARNJNI S Y S T E i However, when a turn signal bulb fails with a
The hazard warning system is activated by a standard flasher, the remaining bulbs in that circuit
switch button in the multi-function switch. The but will light, but not flash. This will give the driver an
ton is located on the top of the steering column indication to check the turn signal bulbs. Because a
between the steering wheel and the instrument heavy-duty flasher has different internal circuitry, a
panel. The hazard warning switch button is identi failed bulb will not prevent the remaining bulbs in
fied with a double triangle. the circuit from flashing. Therefore, it. is recom
The hazard warning system is connected to an mended that an occasional visual inspection of exte
unswitched battery feed so that the system remains rior turn signal lamp operation be performed, when a
functional, regardless of the ignition switch position. heavy-duty flasher has been installed in the place of
Push the switch button i n to activate the hazard the standard flasher.
warning system, and push in on the button again to
turn the system off. When the hazard warning sys HAZARD WARNING FLASHER
tem is activated, the right and left turn signal indi- The hazard warning flasher contains two normally
open contact points mounted to two movable arms. A
8J - 2 TURN SIGNAL AND HAZARD WARNING SYSTEMS BR
DESCRIPTION AND O P E R A T I O N fContinued)

bimetal strip is attached between the two arms. and the rear tail/stop/turn signal. For diagnosis and
When the hazard warning switch is activated, cur service of these lamps, refer to Group 8L - Lamps.
rent flows through the flasher. As the current flows
through the bimetal strip it heats and pulls the mov
able arms together until the contact points close, DIAGNOSIS AND TESTING
allowing current flow to the lamps. As the bimetal
strip cools, the contact points are pushed open and INTRODUCTION
the cycle repeats. When diagnosing the turn signal or hazard warn
ing circuits, remember that high generator output
MULTI-FUNCTION SWITCH can burn out bulbs rapidly and repeatedly. I f this is a
The multi-function switch assembly is mounted to problem on the vehicle being diagnosed, refer to
the left side of the steering column (Fig. 1). This Group 80 - Charging System for further diagnosis.
switch contains circuitry for the following functions:
• Turn signals
BAG, REFER TO GROUP 8M - PASSIVE RESTRAINT
• Hazard warning
SYSTEMS BEFORE ATTEMPTING STEERING
© Headlamp beam selection
WHEEL OR STEERING COLUMN COMPONENT
• Headlamp optical horn
DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
• Windshield wipers
• Windshield washers.
The information contained in this group addresses
PERSONAL INJURY.
only the switch functions for the turn signal and haz
ard warning circuits. For information relative to the
other switch functions, refer to the appropriate TURN SIGNAL SYSTEM
group. However, the multi-function switch cannot be For circuit descriptions and diagrams, refer to
repaired. I f any function of the switch is faulty, the 8W-52 - Turn Signals in Group 8W - Wiring Dia
entire switch assembly must be replaced. grams.
HAZARD WARNING
Move the turn signal lever down for a left turn signal
problem, or up for a right turn signal problem.
Observe the turn signal indicator lamp in the instru
ment cluster. I f the lamp lights but does not flash,
check for an exterior turn signal lamp that is not lit.
Replace the faulty bulb or repair the circuits to that
lamp, as required. Test the turn signal operation
again. I f the turn signal indicator lamp does not light
or still doesn't flash, go to Step 2.
(2) Check the fuse in the fuseblock module. I f OK,
go to Step 3. I f not OK, replace the faulty fuse.
(3) With the ignition switch i n the On position,
check for battery voltage at the fuse in the fuseblock
J938J-3 module. I f OK, go to Step 4. I f not OK, repair the
open circuit as required.
Fig. 1 Multi-Function Switch (4) With the ignition switch in the On position,
place the turn signal lever in the neutral position.
TURN SIGNAL INDICATOR LAMPS
There should be battery voltage at the fused ignition
The turn signal indicator lamps are located in the switch output circuit cavity for the turn signal
instrument cluster. They flash with the exterior turn flasher. I f OK, go to Step 5. I f not OK, repair the
signal lamps to give the driver a visual indication open circuit as required.
that a turn signal or the hazard warning system is (5) Replace the turn signal flasher with a known
operating. For diagnosis and service of this compo good unit of the same rating. The lamps should flash.
nent, refer to Group 8E - Instrument Panel Systems. I f OK, discard the faulty flasher. I f not OK, re-install
the original flasher and go to Step 6.
TURN SIGNAL LAMPS
The exterior lamps in the turn signal and hazard
warning circuits include the front park/turn signal,
mm TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 3
DIAGNOSIS AMP TESTING (Continued)
WARNING: ON VEHICLES EQUIPPED WITH AN AIR- WARNING: ON VEHICLES EQUIPPED WITH AN AIR-
BAG, REFER TO GROUP 8M - PASSIVE RESTRAINT BAG, REFER TO GROUP 8M - PASSIVE RESTRAINT
SYSTEMS BEFORE ATTEMPTING STEERING SYSTEMS BEFORE ATTEMPTING STEERING
WHEEL OR STEERING COLUMN COMPONENT WHEEL OR STEERING COLUMN COMPONENT
DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI PROPER PRECAUTIONS COULD RESULT IN ACCI
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY. PERSONAL INJURY.
(6) Check for continuity between the turn signal (4) Check for continuity between the hazard
flasher signal circuit cavities for the turn signal flasher signal circuit cavities for the hazard flasher
flasher and in the multi-function switch connector. and in the multi-function switch connector. There
There should be continuity. I f OK, see the diagnosis should be continuity. I f OK, see the diagnosis for the
for the multi-function switch in this group. If not OK, multi-function switch in this group. I f not OK, repair
repair the open circuit as required. the open circuit as required.
HAZARD WARNING SYSTEM MULTI-FUNCTION SWITCH

For circuit descriptions and diagrams, refer to Perform the diagnosis of the hazard warning
8W-52 - Turn Signals in Group 8W - Wiring Dia and/or turn signal systems as described in this group
grams. before testing the multi-function switch. For circuit
(1) Check the fuse in the Power Distribution Cen descriptions and diagrams, see 8W-52 - Turn Signals
ter (PDC). I f OK, go to Step 2. I f not OK, replace the in Group 8W - Wiring Diagrams.
faulty fuse.
(2) Check for battery voltage at the fused B(+) cir WARNING: ON VEHICLES EQUIPPED WITH AN AIR-
cuit cavity for the hazard warning flasher. I f OK, go BAG, REFER TO GROUP 8M - PASSIVE RESTRAINT
to Step 3. I f not OK, repair the open circuit as SYSTEMS BEFORE ATTEMPTING STEERING
required. WHEEL OR STEERING COLUMN COMPONENT
(3) Replace the hazard flasher with a known good DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
unit of the same rating. With the hazard warning PROPER PRECAUTIONS COULD RESULT IN ACCI
switch in the On position, the lamps should flash. I f DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
OK, discard the faulty flasher. I f not OK, re-install PERSONAL INJURY.
the original flasher and go to Step 4.
SJ - 4 TURN SIGNAL AND HAZARD WARNING SYSTEMS

(1) Disconnect the multi-function switch connector
as described in this group.
(2) Using an ohmmeter, perform the switch conti
nuity checks at the switch terminals as shown in the
chart (Fig. 2).
(3) I f the switch fails any of the continuity checks, BUZZER
replace the faulty switch. I f the switch is OK, repair MODULE
the lighting circuits as required.
HAZARD WARNING/TURN SIGNAL FLASHER

cable.
(2) Open the driver's door and remove the snap-in
fuseblock module cover on the left end of the instru
ment panel (Fig. 3). Fig. 3 Fuseblock Module
(3) Unplug the flasher from the fuseblock module.
(4) To install the flasher, align the terminals with
the cavities in the fuseblock module and push the
flasher firmly into place.
(5) Reverse the remaining removal procedures to
complete the installation.
VIEW FROM TERMINAL CASE
SWITCH POSITIONS
TURN SIGNAL HAZARD WARNING CONTINUITY BETWEEN
NEUTRAL OFF 12 AND 14 AND 15
LEFT OFF 15 AND 16 AND 17

LEFT OFF 12 AND 14
LEFT OFF 22 AND 23 WITH OPTIONAL CORNER LAMPS
RIGHT OFF 11 AND 12 AND 17

RIGHT OFF 14 AND 15
RIGHT OFF 23 AND 24 WITH OPTIONAL CORNER LAMPS
NEUTRAL ON 11 AND 12 AND 13 AND 15 AND 16
908J-4
Fig. 2 Multi-Function Switch Continuity

BR TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 5

MULTI-FUNCTION SWITCH UPPER
SHROUD
WARNING; ON VEHICLES EQUIPPED WITH AN AIR-
SYSTEMS BEFORE ATTEMPTING STEERING
WHEEL OR STEERING COLUMN COMPONENT
PERSONAL INJURY.

cable.
(2) Remove the tilt steering column lever, i f
equipped.
(3) Remove both the upper and lower shrouds from
the steering column (Fig. 4).
(4) Remove the lower fixed column shroud.
(5) Move the upper fixed column shroud to gain
access to the rear of the multi-function switch (Fig.
LOWER
5). SHROUD J9419-17
(6) Remove the multi-function switch tamper proof
mounting screws (a Snap On tamper proof torx bit
Fig. 4 Steering Column Shrouds Remove/Install
TTXR20B2 or equivalent is required).
(7) Gently pull the switch away from the column.
Loosen the connector screw. The screw will remain in
the connector.
(8) Remove the wiring connector from the multi
function switch.
Tighten the fasteners as follows:
• Multi-function switch connector screw - 1.9 N-m
(17 in. lbs.)
• Multi-function switch retaining screws - 1.9 N-m
(17 in. lbs.).
J918J-1 CONNECTOR
Fig. 5 Multi-Function Switch Connector

BR WIPER AND WASHER SYSTEMS 8K -1
WIPER AND WASHER SYSTEMS

CONTENTS
page page
GENERAL INFORMATION MULTI-FUNCTION SWITCH 6

INTRODUCTION 1 WASHER PUMP 7
DESCRIPTION AND OPERATION WIPER AND WASHER SYSTEMS 3
INTERMITTENT WIPE MODULE 2 WIPER MOTOR 4
WASHER NOZZLES AND PLUMBING 3 REMOVAL AND INSTALLATION
WASHER PUMP 3 INTERMITTENT WIPE MODULE 10
WASHER RESERVOIR 3 MULTI-FUNCTION SWITCH 10
WINDSHIELD WASHER SYSTEM 1 WASHER PUMP AND RESERVOIR 11
WINDSHIELD WIPER SYSTEM 1 WIPER ARM 8
WIPER AND WASHER SWITCHES 2 WIPER BLADES AND ELEMENTS 7
WIPER ARMS AND BLADES 1 WIPER LINKAGE AND PIVOTS 10
WIPER LINKAGE AND PIVOTS 2 WIPER MOTOR, 9
WIPER MOTOR 2
INTERMITTENT WIPE MODULE 6
GENERAL INFORMATION An optional low washer fluid warning lamp on the

instrument panel will warn the driver when the
INTRODUCTION washer fluid level needs to be checked. Refer to
Following are general descriptions of the major Group 8E - Instrument Panel Systems for more infor- •
components in the wiper and washer systems. Refer mation on this feature.
to 8W-53 - Wipers in Group 8W - Wiring Diagrams The washers will operate only when - the ignition
for complete circuit descriptions and diagrams. switch is in the Accessory or On positions. A fuse in
the fuseblock module protects the circuitry of the
washer system. Refer to the owner's manual for more
DESCRIPTION AND OPERATION information on washer system controls and operation.
WINDSHIELD WIPER SYSTEM WIPER ARMS AND BLADES

An intermittent wiper system is standard equip All Ram truck models have two 20-inch wiper
ment. This system lets the driver select from two blades with replaceable rubber elements (squeegees).
wiper speeds, or an intermittent wipe feature that These wiper blades include an anti-lift feature. These
allows a delay between wipes of 2 to 15 seconds. blades and squeegees must be oriented correctly
The wipers will' operate only when the ignition when installed on the wiper arms for the anti-lift fea
switch is i n the Accessory or On positions. A fuse in ture to be effective. See Removal and Installation i n
the fuseblock module protects the circuitry of the this group for more information.
wiper system. Refer to the owner's manual for more Caution should be exercised to protect the rubber
information on wiper system controls and operation. squeegees from any petroleum-based cleaners or con
taminants, which will rapidly deteriorate the rubber.
WINDSHIELD WASHER SYSTEM If the squeegees are damaged, worn, or contaminated
A electrically operated windshield washer system is they must be replaced.
standard equipment. A reservoir in the engine com Wiper squeegees exposed to the elements for a long
partment holds the washer fluid, which is pressur time tend to lose their wiping effectiveness. Periodic
ized by a pump when the washer (multi-function) cleaning of the squeegees is suggested to remove
switch is actuated. The washer pump feeds the pres deposits of salt and road film. The wiper blades,
surized washer fluid through the washer system arms, and windshield should be cleaned with a
plumbing to the washer nozzles. sponge or cloth and a mild detergent or non-abrasive
81 - 2 WIPER AND WASHER SYSTEMS
DESCRIPTION AHP OPERATION (Continued)

cleaner. I f the squeegees continue to streak or smear, WIPER AND WASHER SWITCHES
they should be replaced. The wiper and washer switches are contained in
The blades are mounted to two spring-loaded wiper the multi-function switch assembly. The multi-func
arms. Spring tension of the wiper arms controls the tion switch assembly is mounted to the left side of
pressure applied to the blades on the windshield. The the steering column (Fig. 1). This switch contains cir
wiper arms are attached by an integral latch to the cuitry for the following functions:
two wiper pivots on the cowl plenum cover/grille • Turn signals
panel at the base of the windshield. The wiper arms • Hazard warning
and blades cannot be adjusted or repaired. I f faulty, • Headlamp beam selection
they must be replaced. • Headlamp optical horn
© Windshield wipers
WIPER LINKAGE AND PIVOTS • Windshield washers.
The wiper linkage and pivot module is fastened The information contained i n this group addresses
with screws to the cowl plenum panel beneath the only the switch functions for the wiper and washer
cowl plenum cover/grille panel. The wiper motor is systems. For information relative to the other switch
fastened with screws to the center of the linkage and functions, refer to the appropriate group. However,
pivot module bracket. The wiper pivots are fastened the multi-function switch cannot be repaired. I f any
to the ends of the module bracket. function of the switch is faulty, the entire switch
The two wiper pivot crank arms and the wiper assembly must be replaced.
motor crank arm each have ball studs on their ends.
The motor crank arm ball stud is the longer of the HAZARD W A R N I N G
three. Two drive links connect the motor crank arm
to the pivot crank arms. The right drive link has a
plastic socket-type bushing on each end. The left
drive link has a plastic socket-type bushing on one
end, and a plastic sleeve-type bushing on the other
end. The socket-type bushing on one end of each
drive link is fit over the ball stud on the crank arm
of its respective pivot. The left drive link sleeve-type
bushing end is-then fit over the motor crank arm ball
stud, and the other socket-type bushing of the right
drive link is snap-fit over the exposed end of the
motor crank arm ball stud.
The wiper linkage, pivots, bushings, and mounting
J938J-3
bracket are only serviced as a complete unit. I f any
part of this assembly is faulty, the entire unit must
Fig. 1 Multi-Function Switch
be replaced. The wiper motor and motor crank arm
are serviced separately. INTERMITTENT WIPE MODULE
In addition to low and high speed, the intermittent
WIPER MOTOR wipe system has a delay mode. The delay mode has a
The two-speed permanent magnet wiper motor has range of two to fifteen seconds.
an integral transmission and park switch. The motor The length of the delay is selected with a variable
is mounted to the wiper linkage and pivot module resistor i n the wiper (multi-function) switch, and is
bracket with three screws. The motor output shaft accomplished by electronic circuitry within the inter
passes through a hole in the module bracket, where a mittent wipe module. If the washer knob is depressed
nut secures the wiper motor crank arm to the motor while the wiper switch is in the Off position, the
output shaft. intermittent wipe module will operate the wiper
Wiper speed is controlled by current flow to the motor for approximately two wipes and automatically
appropriate set of brashes. The wiper motor com turn off the motor.
pletes its wipe cycle when the wiper/washer (multi The intermittent wipe module is snap-fit onto a
function) switch is turned to the Off position, and single blade-type mounting bracket located under the
parks the blades in the lowest portion of the wipe instrument panel, The module cannot be repaired
pattern. The wiper motor cannot be repaired. I f and, i f faulty, must be replaced.
faulty, the entire wiper motor assembly must be
replaced. The motor crank arm and the linkage and
pivot module are available for service.
BR WIPER AND WASHER SYSTEMS 8K - 3
WASHER RESERVOIR tee fitting located in the cowl plenum area beneath
The washer fluid reservoir is mounted to the left the cowl plenum cover/grille panel. Hoses from the
side of the radiator fan shroud i n the engine com tee fitting are routed to the two nozzles, which are
partment. The washer pump and motor unit has a snap-fit into openings in the cowl plenum cover/grille
threaded nipple, which is press-fit into a grommet panel. The hoses are clipped to the underside of the
seal inserted in a hole in the bottom of the reservoir. cowl plenum cover/grille panel.
The reservoir also has a provision for a low washer The two fluidic washer nozzles are not adjustable.
fluid level sensor. Refer to Group 8E - Instrument Panel The nozzles cannot be repaired and, i f faulty, must be
Systems for diagnosis and service of the sensor. The res replaced.
ervoir and filler cap are each available for service.
WASHER PUMP
The washer pump and motor are mounted near the
WIPER AND WASHER SYSTEMS
bottom of the washer reservoir. A threaded nipple on
the pump housing is press-fit into a rubber grommet WARNING: ON VEHICLES EQUIPPED WITH AN AIR-
seal installed in the bottom of the reservoir. BAG, REFER TO GROUP 8M - PASSIVE RESTRAINT
A permanently lubricated and sealed motor is coupled SYSTEMS BEFORE ATTEMPTING STEERING
to a rotor-type pump. Washer fluid is gravity-fed from WHEEL OR STEERING COLUMN COMPONENT
the reservoir to the pump. The pump then pressurizes DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
the fluid and forces it through the plumbing to the noz PROPER PRECAUTIONS COULD RESULT IN ACCI
zles, when the motor is energized. The pump and motor DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
cannot be repaired. I f faulty, the entire washer pump PERSONAL INJURY
and motor unit must be replaced.
WASHER NOZZLES AND PLUMBING

Pressurized washer fluid is fed through a single
hose, attached to a nipple on the washer pump, to a
Wiper and Washer Systems Diagnosis

WIPER MOTOR WILL NOT RUN. 1 Fuse faulty. 1. Check fuse in fuseblock module.
2. Switch faulty. Replace fuse, if required.
3. Wiring faulty. 2. See Multi-Function Switch tests, in
4. Ground faulty. this group. Replace switch, if required.
5. Motor faulty. 3. Refer to Group 8W - Wiring
Diagrams. Check continuity between
switch and motor. Repair wiring, if
required.
4. Check for continuity between motor
ground strap and a known good
ground. Repair ground circuit, if
required.
5. See Wiper Motor tests, in this group.
Replace wiper motor, if required.
WIPER MOTOR RUNS, BLADES 1. Loose motor crank arm. 1. Tighten motor crank arm nut, if
DO NOT MOVE. 2. Linkage disconnected. required.
3. Faulty pivots. 2. Re-install linkage or replace linkage
4 Faulty motor. assembly, if required.
3. Replace linkage assembly if
required.
8K - 4 WIPER AND WASHER SYSTEMS — BR
Wiper and Washer Systems Diagnosis

BLADES DO NOT PARK 1. Wiper arms improperly installed. 1. See Wiper Arm installation
PROPERLY. 2. Faulty linkage. procedure, in this group. Re-install
3. Wiring faulty. wiper arms, if required.
4. Switch faulty. 2. Replace linkage assembly, if
5. Motor faulty. required.
3. Refer to Group 8W - Wiring
Diagrams. Check continuity between
switch and motor. Repair wiring, if
required.
4. See Multi-Function Switch tests, in
this group. Replace switch, if required.
WIPER KNOCK NOISE. 1. Wiper arms improperly installed. 1. See Wiper Arm installation
2. Faulty linkage. procedure, in this group. Re-install
3. Motor faulty wiper arms, if required.
2. Replace linkage assembly, if
required.
3. Replace worn motor, if required
BLADES CHATTER. 1. Contaminated glass or blade 1. Clean glass thoroughly and replace
elements. blade elements, if required.
2. Wiper arm faulty. 2. Twisted arm holds blade at wrong
3. Wiper blade faulty. angle. Replace arm, if required.
3. Replace damaged or worn blade, if
1
required.
WASHERS DO NOT OPERATE. 1. No fluid in reservoir. 1. Fill reservoir, if required.
2. Contaminated fluid. 2. Drain and flush system, if required.
3. Mis-routed or leaking plumbing. 3. Re-route pinched or kinked hoses.
4. Wiring faulty. Replace leaking hoses or fittings.
5. Switch faulty. 4. Refer to Group 8W - Wiring
6. Pump faulty. Diagrams. Check continuity between
switch and pump. Repair wiring, if
required.
5. See Multi-Function Switch tests, in
this group. Replace switch, if required.
6. See Washer Pump tests, in this
group. Replace pump, if required.
WIPER MOTOR PROCEDURE

The following are wiper motor problems, tests to be (1) Check the fuse in the fuseblock module. I f OK,
performed to locate the faulty component, and the go to Step 3. I f not OK, replace the faulty fuse and go
proper action to be taken. I f the problem involves to Step 2.
only the delay mode, the wiper/washer switch, or the (2) Check the wiper motor operation in all wiper/
wiring, see the diagnosis for Intermittent Wipe Mod washer switch positions. I f not OK and the fuse
ule and Multi-Function Switch in this group. For cir blows, go to Step 5. I f not OK and the fuse is OK, go
cuit descriptions and diagrams, refer to 8W-53 - to Step 3.
Wipers in Group 8W - Wiring Diagrams. (3) Place the wiper/washer switch in the Low posi
tion and listen to the motor. I f you cannot hear i t
CONDITION running, go to Step 4. I f the motor is running, check
The wiper motor will not run in any wiper/ the motor output shaft. I f the output shaft is not
washer switch position. turning, replace the faulty wiper motor assembly. I f
BR WiPEi AND WASIEFt SYSTEMS 81 - 5

it is turning, the crank arm is not connected to the TERMINAL AMMETER
output shaft or the linkage is not properly connected.
Replace the faulty linkage assembly and/or properly
connect the crank arm to the motor output shaft.
(4) Connect a voltmeter between the motor termi
nal L and the ground strap (Fig. 2). I f there is little
or no voltage (less than 1 volt), move the negative
test lead from the ground strap to the battery nega
tive terminal. I f an increase in voltage is noticed, the
problem is a bad ground circuit. Make sure the motor
mounting is free of paint and that the mounting fas
teners are tight. I f there is still no indication of volt
age, the problem is an open in the wiring or a faulty
multi-function switch. I f a small increase (greater
than 3 volts) in voltage is observed, the problem is a
Fig. 3 Ammeter Between Terminal L and Battery
faulty wiper motor assembly.
(3) Check the motor wiring harness for a short
VOLTMETER WiPEi
between the high and low speed circuits. Connect a
voltmeter or test lamp to the motor ground strap. Set
the wiper/washer switch in the Low position. Connect
the other lead of the voltmeter or test lamp to termi
nal H of the wiring harness. I f voltage is present,
there is a short in the wiring or multi-function
switch. I f no voltage is present, go to Step 4.
(4) Set the wiper/washer switch i n the High posi
tion. Move the voltmeter or test lamp lead from ter
minal H to terminal L of the wiring harness. I f
voltage is present, there is a short i n the wiring or
the multi-function switch.
CONDITION
The wiper motor will run at h i g h speed, but
not at low speed.
Fig. 2 Voitmeter Between Terminal L and Ground The wiper motor will run at low speed, but
(5) Disconnect the motor wiring connector and not at h i g h speed.
replace the fuse. I f the fuse does not blow, the wiper
PROCEDURE
motor is faulty. I f the fuse blows, the multi-function
switch or the wiring is at fault. (1) I f the motor will not run on high speed, set the
wiper/washer switch i n the High position. Connect a
CONDITION test lamp between the motor terminal H and a good
The wiper motor runs slowly at all speeds. ground (Fig. 4). I f the motor will not run on low
speed, set the wiper/washer switch i n the Low posi
PROCEDURE tion. Connect a test lamp between the motor termi
(1) Disconnect the wiring harness connector at the nal L and a good ground.
wiper motor. Remove the wiper arms and blades. (2) I f the test lamp does not light at the motor ter
Connect an ammeter between the battery and termi minal, there is an open in the wiring or the multi
nal L on the motor (Fig. 3). I f the motor runs and the function switch. I f the test lamp lights at the motor
average ammeter reading is more than 6 amps, go to terminal, replace the faulty motor assembly.
Step 2. I f the motor runs and the average ammeter
reading is less than 6 amps, go to Step 3. CONDITION
(2) Check the wiper linkage or pivots for binding The wiper motor will keep running with the
or obstruction. Disconnect the drive links from the wiper/washer switch in the Off position.
motor. I f the motor now runs and draws less than 3
amps, repair the linkage system. I f the motor contin PROCEDURE
ues to draw more than 3 amps, replace the faulty (1) Disconnect the wiring harness connector at the
motor assembly. motor. Connect a jumper wire from terminal P2 to
terminal L of the wiper motor (Fig. 5).
81 - 6 WIPER AND WASHER SYSTEMS — BR
DIAGNOSIS - H D TESTING (Continued)
TERMINAL T E S T (3) Connect an ohmmeter or continuity tester
between terminals L and P2 (Fig. 6). I f there is con
tinuity between these terminals, the problem is a
faulty motor. I f there is no continuity, the problem is
an open i n the wiring or a faulty multi-function
switch.
OHMMETER TERMINALS
J948K-25
Fig. 4 Test Lamp Between Terminal H and Ground
Fig. 6 Ohmmeter Between Terminal L and P2

MULTI-FUNCTION SWITCH
Perform the diagnosis for the wiper and/or washer
systems as described i n this group before testing the
multi-function switch. For circuit descriptions and
diagrams, see 8W-53 - Wipers in Group 8W - Wiring
Diagrams.
;-26
Fig. 5 One Jumper Wire Between Terminal P2 and L BAG, REFER TO GROUP 8M - PASSIVE RESTRAINT
- One Jumper Wire Between Terminal P1 and B+ SYSTEMS BEFORE ATTEMPTING STEERING
(2) Connect a second jumper from terminal P I to WHEEL OR STEERING COLUMN COMPONENT
the battery. I f motor runs to the park position and DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
stops, the multi-function switch is faulty. I f the motor PROPER PRECAUTIONS COULD RESULT IN ACCI
keeps running and does not park, replace the faulty DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
motor assembly. PERSONAL INJURY.
CONDITION (1) Disconnect the multi-function switch connector

The wiper motor will stop when wiper/washer as described in this group.
switch is set in the Off position, but the wipers (2) Using an ohmmeter, perform the switch conti
do not continue running to the park position. nuity checks at the switch terminals as shown in the
chart (Fig. 7).
PROCEDURE (3) I f the switch fails any of the continuity checks,
(1) Remove the motor wiring connector and clean replace the faulty switch.
the terminals. Reconnect the wiring and test the
motor. I f not OK, go to Step 2. INTERMITTENT WIPE MODULE
(2) Set the wiper/washer switch in the Off position. See the diagnosis for the Wiper Motor or Multi-
Disconnect the motor wiring connector. Connect a Function Switch i f the problems do not involve the
voltmeter or test lamp to the motor ground strap. Delay function. I f the problem occurs only in the
Connect the other lead to terminal P I of the wiring Delay mode, the following tests are to be performed.
connector. I f voltage is not present, check for an open For circuit descriptions and diagrams, refer to 8W-53
circuit i n the wiring harness or multi-function - Wipers in Group 8W - Wiring Diagrams.
switch. I f voltage is present, go to Step 3.
WIPER AND WASHER SYSTEMS 8K - 7
(2) Verify that the wiper motor ground strap con
JJ 24 23 22 j» 20 j£ Tg^ |1 nections are clean and tight, and that the wiper
17 16 15 14 / r ^ \ 1 3 12 11 10 j motor mounting bolts are tight.
9 8 7 6 V
5^4 3 2 1 (3) Verify that the ground circuit connections for
the intermittent wipe module and the wiper/washer
(multi-function) switch are clean and tight.
MULTIFUNCTION SWITCH PINS
If all of the above grounds are confirmed OK and
SWITCH
the condition is not corrected, replace the faulty
POSITION intermittent wipe module.
OFF PM 6 ANSD FSN 7 |
PIN 8 AND FIN 9 WASHER PUMP
PIN 2 AND PIN 4 For circuit descriptions and diagrams, refer to
DELAY
PIN 1 AND PIN 2
PIN 1 AND PIN 4
8W-53 - Wipers in Group 8W - Wiring Diagrams.
LOW PIN 4 A N D PIN 6 (1) Check for continuity between the ground cir
HIGH PIN 4 AND PIN 5 cuit cavity of the pump connector and a good ground.
WASH PIN 3 A N D PIN 4
There should be continuity. I f OK, go to Step 2. I f not
* RESISTANCE AT MAXIMUM DELAY POSITION SHOULD BE
OK, repair the open circuit as required.
BETWEEN 270,000 OHMS A N D 330,000 OHMS. (2) Turn the ignition switch to the On position.
* RESISTANCE AT MINIMUM DELAY POSITION SHOULD BE Check for battery voltage at the washer pump control
ZERO WITH OHMMETER SET O N HIGH OHM SCALE. circuit output cavity of the pump connector with the
918J-4 washer switch depressed. I f OK, replace the faulty
washer pump. I f not OK, see the diagnosis for the
Fig. 7 Multi-Function Switch Continuity Multi-Function Switch in this group. I f the switch
CONDITION tests OK, repair the circuits between the switch and
Excessive delay (more than 30 seconds) or the washer pump as required.
inadequate variation in the delay.
PROCEDURE
Variations i n the delay should be as follows: WIPEFt BLADES AND ELEMENTS
(1) Minimum delay (wiper/washer switch to The wiper blade and element are an anti-lift
extreme counterclockwise position before Low detent) design, so as to resist the effects of air lifting the
- 1/2 to 2 seconds. blade and element off the windshield glass in high
(2) Maximum delay (wiper/washer switch to winds or at highway speeds. However, in order for
extreme clockwise position before Off detent) - 10 to this feature to be effective, the wiper blades and ele
30 seconds. ments must be properly oriented on the windshield.
If there is excessive delay or no variation in the Note that the center bridge of the wiper arm has a
delay, see the Multi-Function Switch tests. long leading edge, and a short trailing edge. When
the wipers are in the Park position, the leading edge
CONDITION
of the wiper blade must always be oriented towards
In the Delay mode the wipers run continually
the base of the windshield. Also note that the pinch-
when the washers are operated, but do not pro
release for the wiper element should always be ori
vide an extra wipe when the washer switch is
ented towards the end of the wiper blade that is
released.
nearest to the wiper pivot.
PROCEDURE To remove the wiper blade and/or element, proceed
Replace the faulty intermittent wipe module. as follows:
(1) Turn the wiper/washer switch to the On posi
CONDITION tion. By turning the ignition switch to the On and
The wipers start erratically during the Delay Off positions, cycle the wiper blades to a convenient
mode. working location on the windshield.
(2) Lift the wiper arm to raise the wiper blade and
PROCEDURE element off of the windshield glass.
Perform the following checks: (3) Remove the wiper blade from the wiper arm, or
(1) Verify that the ground connection at the instru the wiper element from the wiper blade as follows:
ment panel is clean and tight. (a) To remove the wiper blade from the wiper
arm, push the release tab under the arm tip and
8K - 8 W i P E i AND WASHE1 SYSTEMS BR
slide the blade away from the tip towards the pivot W i P E i AFti
end of the arm (Fig. 8).
(b) To remove the wiper element from the wiper CAUTION: The use of a screwdriver or other prying
blade, pinch the notched (pivot) end of the wiper tool to remove a wiper arm may distort it. This dis
element tightly between the thumb and forefinger tortion could allow the arm to come off of the pivot
(Fig. 9). Then, pull the element firmly towards the shaft, regardless of how carefully it is installed.
wiper pivot to release the wiper blade claw from
the wiper element retaining pocket. Once the claw (1) Lift the wiper arm to permit the latch to be
is released from the pocket, the element will slide pulled out to the holding position, then release the
easily out of the remaining claws. arm (Fig. 10). The arm will remain off the windshield
with the latch in this position.
UNLOCKED
POSITION
LOCKED
POSITION
J948K-21
Fig. 8 Wiper Blade Remove/install

Fig. 10 Wiper Arm Remove/Install
CLAW
(2) Remove the arm from the pivot using a rocking
motion.
TO GRASP
(3) Install the arm and blade with the wiper motor
A N D PULL
in the Park position. See the Wiper Arm Installation
illustration (Fig. 11). Mount the arms on the pivot
shafts so that the distance of the wiper blade tip
from the upper edge of the lower windshield blackout
area is ± 22 mm (0.86 in.).
RUBBER
ELEMENT CHANNEL 918K-8 BLACK OUT
AREA
Fig. 9 Wiper Element Remove

(4) Install the wiper blade on the wiper arm, or
the wiper element in the wiper blade as follows:
(a) To install the wiper blade on the wiper arm,
slide the blade retainer into the U-shaped forma
tion on the tip of the wiper arm until the release
tab snaps into its locked position. Be certain that TIP OF BLADE ± 22MM FROM EDGE OF BLACK OUT
J948K-22
the leading edge of the blade center bridge is ori
ented towards the base of the windshield. Fig. 11 Wiper Arm Installation
(b) To install the wiper element in the wiper
blade, be certain that the metal element rails (ver (4) Lift the wiper arm away from the windshield
tebra) are properly seated in the slots on either slightly to relieve the spring tension on the locking
side of the rubber element. Starting at the wiper latch. Push the latch into the locked position and
pivot end of the blade, slide the element through slowly release the arm until the wiper blade rests on
each pair of wiper blade claws. The element is fully the windshield.
installed when the claws on the wiper pivot end of (5) Operate the wipers with the windshield glass
the blade are engaged in the wiper element retain wet, then turn the wiper switch to the Off position.
ing pockets. Check for the correct wiper arm positioning and re
adjust i f required.
BR WIPER AND WASHER SYSTEMS 8K - 9

WIPER MOTOR
cable.
(2) Remove the wiper arms as described in this
group.
(3) Remove the weatherstrip along the front edge
of cowl plenum cover/grille panel (Fig. 12).
Fig. 12 Cowl Plenum Cover/Grille Panel

Weatherstrip
(4) Release the plastic anchor screws (Fig. 13).
Fig. 15 Linkage and Pivots Module Mounting Bolts
Fig. 16 Wiper Motor Connectors

(9) Remove the drive links from the wiper motor
crank arm by prying the retainer bushing from the
Fig. 13 Plastic Anchor Screws Remove/Install crank arm ball stud with a suitably sized screwdriver
(5) Lift the cowl plenum cover/grille panel from the (Fig. 17).
vehicle. (10) Remove the three screws securing the wiper
(6) Remove the washer nozzle hoses from the sup motor to the linkage module bracket and remove the
ply hose at the tee fitting (Fig. 14). Set the cowl ple motor.
num cover/grille panel aside. (11) Remove the nut attaching the motor crank
(7) Remove the wiper linkage and pivots module arm to the motor output shaft.
mounting bolts (Fig. 15). (12) Remove the crank arm from the motor.
(8) Turn the wiper linkage module over and (13) To install, position the crank arm on the
unplug the wiring harness and ground tab connectors motor output shaft being certain that the crank arm
from the wiper motor (Fig. 16). slot is indexed properly to the output shaft. Install
8 K - 10 WIPER AND WASHER SYSTEMS
mm
Fig. 17 Wiper Motor/Linkage and Pivots Remove/

Install
the crank arm nut to the output shaft and tighten to
14 N-m (11 ft. lbs.).
(14) Install the drive links to the crank arm ball
stud and snap together using channel-lock pliers.
Fig. 18 Intermittent Wipe Module Remove/Install
(15) Position the motor on the linkage module
bracket. Install the motor mounting screws and (1) Disconnect and isolate the battery negative
tighten to 6 N-m (55 in. lbs.). cable.
(16) Reverse the remaining removal procedures to (2) Remove the tilt steering column lever, i f
complete the installation. equipped.
(3) Remove both the upper and lower shrouds from
WIPER LINKAGE AND PIVOTS the steering column (Fig. 19).
The wiper linkage and pivots can only be removed
UPPER
or installed as a unit with the wiper motor. See SHROUD
Wiper Motor in this group for the procedures.
INTERMITTENT WIPE MODULE

cable.
(2) Remove the knee blocker as described in Group
8E - Instrument Panel Systems.
(3) Unplug the harness connector from the inter
mittent wipe module (Fig. 18).
(4) Disengage the intermittent wipe module snap-
fit mounting slot from the blade of the mounting
bracket.
MULTI-FUNCTION SWITCH

SYSTEMS BEFORE ATTEMPTING STEERING LOWER
WHEEL OR STEERING COLUMN COMPONENT SHROUD J9419-17

PROPER PRECAUTIONS COULD RESULT IN ACCI Fig. 19 Steering Column Shrouds Remove/Install
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE (4) Remove the lower fixed column shroud.
PERSONAL INJURY.
BR WIPER AND WASHER SYSTEMS 8K -11

(5) Move the upper fixed column shroud to gain WASHER PUMP AND RESERWOIR
access to the rear of the multi-function switch (Fig. (1) Disconnect and isolate the battery negative
20). cable.
(2) Drain the engine coolant and remove the upper
radiator hose from the radiator. Refer to Group 7 -
Cooling System for the procedures.
(3) Remove the hose from the washer pump and
drain the washer fluid from the reservoir into a clean
container for reuse.
(4) Unplug the connectors from the washer pump
and the washer fluid level sensor, i f equipped (Fig.
21).
Fig. 20 Multi-Function Switch Connector

(6) Remove the multi-function switch tamper proof
mounting screws (a Snap On tamper proof torx bit
TTXR20B2 or equivalent is required).
(7) Gently pull the switch away from the column.
Loosen the connector screw. The screw will remain in
the connector.
(8) Remove the wiring connector from the multi WASHER PUMP J948K-18
function switch.
Fig. 21 Washer Fluid Reservoir Remove/Install
Tighten the fasteners as follows: (5) Pull the reservoir up and out of the radiator
• Multi-function switch connector screw - 1.9 N-m shroud.
(17 in. lbs.) (6) Gently pry the pump out of the grommet seal
• Multi-function switch retaining screws -1.9 N-m and/or the fluid level sensor away from the reservoir.
(17 in. lbs.). Care must be taken not to puncture the reservoir.
(7) Remove the rubber grommet seal from the res
ervoir and discard.
Always use a new rubber grommet on the reservoir.
BR LAMPS 8L - 1
LAMPS
CONTENTS
page page
BULB APPLICATION 16 LAMP DIAGNOSIS 1

HEADLAMP ALIGNMENT 5 LAMP SERVICE 11
LAMP BULB SERVICE 8 LAMP SYSTEMS 15
LAMP DIAGNOSIS
INDEX
page page
GENERAL INFORMATION DIAGNOSIS AND TESTING

DAYTIME RUNNING LAMPS 1 DIAGNOSTIC PROCEDURES 1
GENERAL INFORMATION 1 FOG LAMP DIAGNOSIS 4
SAFETY PRECAUTIONS 1 HEADLAMP DIAGNOSIS 2
GENERAL INFORMATION When i t is necessary to remove components to ser

vice another, i t should not be necessary to apply
GENERAL INFORMATION excessive force or bend a component to remove it.
Each vehicle is equipped with various lamp assem Before damaging a trim component, verify hidden
blies. A good ground is necessary for proper lighting fasteners or captured edges are not holding the com
operation. Grounding is provided by the lamp socket ponent in place.
when it comes in contact with the metal body, or
through a separate ground wire. DAYTIME RUNNINO LAMPS
When changing lamp bulbs check the socket for The daytime running lamps are controlled by the
corrosion. I f corrosion is present, clean it with a wire Daytime Running Lamp Relay (DRLR). The DRLR is
brush and coat the inside of the socket lightly with located in the engine compartment on the left fender
Mopar Multi-Purpose Grease or equivalent. wheelhouse. The DRLR allows the high beam head
lamps to illuminate at 50% of the switched ON
SAFETY PRECAUTIONS brightness when the engine is running with the
headlamp switch OFF. The Daytime running lamps
WARNING; EYE PROTECTION SHOULD BE USED will go out when the headlamp switch is pulled out.
WHEN SERVICING GLASS COMPONENTS, PER The passing light feature will flash bright high
SONAL INJURY CAN RESULT beams while the daytime ~ running lamps are acti
vated.
CAUTION: Do not touch the glass of halogen bulbs

with fingers or other possibly oily surface, reduced DIAGNOSIS AND T E S T I N G
bulb life will result.
Do not use bulbs with higher candle power than DIAlNOSTiC PROCEDURES
indicated in the Bulb Application table at the end of When a vehicle experiences problems with the
this group. Damage to lamp can result. headlamp system, verify the condition of the battery
Do not use fuses, circuit breakers or relays hav connections, charging system, headlamp bulbs, wire
ing greater amperage value than indicated on the connectors, relay, high beam dimmer switch and
fuse panel or in the Owners Manual. headlamp switch. Refer to Group 8W, Wiring Dia-
8L - 2 LAMPS
grams for component locations and circuit informa
tion.
HEADLAMP DIAGNOSIS
Always begin any diagnosis by testing all of the
fuses and circuit breakers i n the system. Refer to
Group 8W, Wiring Diagrams.
Conventional and halogen headlamps are inter
changeable. I t is recommended that they not be
intermixed on a given vehicle.
HEADLAMP DIAGNOSIS
HEADLAMPS ARE DIM 1. Loose or corroded battery 1. Clean and secure battery cable clamps and posts.
WITH ENGINE IDLING cables.
OR IGNITION TURNED 2. Loose or worn generator 2. Adjust or replace generator drive belt.
OFF. drive belt.
3. Charging system output 3. Test and repair charging system, refer to Group 8A.
too low.
4. Battery has insufficient charge. 4. Test battery state-of-charge, refer to Group 8A.
5. Battery is sulfated or shorted. 5. Load test battery, refer to Group 8A.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across Z1-ground locations,
refer to Group 8W.
7. Both headlamp bulbs 7. Replace both headlamp bulbs.
defective.
HEADLAMP BULBS 1. Charging system output 1. Test and repair charging system, refer to Group 8A.
BURN OUT too high.
FREQUENTLY. 2. Loose or corroded terminals or 2. Inspect and repair all connectors and splices, refer to
splices in circuit. Group 8W.
HEADLAMPS 1. Charging system output 1. Test and repair charging system, refer to Group 8A.
ARE DIM WITH ENGINE too low.
RUNNING ABOVE IDLE.* 2. Poor headlamp circuit 2. Test voltage drop across Z1 -ground, refer to Group 8W.
ground.
3. High resistance in headlamp . 3. Test amperage draw of headlamp circuit.
circuit.
4. Both headlamp bulbs 4. Replace both headlamp bulbs.
defective.
HEADLAMPS 1. Poor headlamp circuit 1. Repair circuit ground, refer to Group 8W.
FLASH RANDOMLY. ground.
2. High resistance in headlamp 2. Test amperage draw of headlamp circuit.
circuit.
3. Faulty headlamp switch 3. Replace headlamp switch.
circuit breaker.
4. Loose or corroded terminals 4. Repair connector terminals or splices, refer to Group 8W.
or splices in circuit.
HEADLAMPS 1. No voltage to headlamps. 1. Replace fuse, refer to group 8W.

DO NOT ILLUMINATE. 2. No ground at headlamps. 2. Repair circuit ground, refer to Group 8W.
3. Faulty headlamp switch. 3. Replace headlamp switch.
4. Faulty headlamp dimmer 4. Replace headlamp dimmer switch.
switch.
5. Broken connector terminal or 5. Repair connector terminal or wire splices.
wire splice in headlamp circuit.
* Canada vehicles must have lamps ON.
J958L-5
8L - 4 LAMPS — BR
FOG LAMP DIAGNOSIS
FOG LAMPS ARE DIM 1. Loose or corroded battery 1. Clean a n d secure battery cable clamps a n d posts.
W I T H E N G I N E IDLING cables.
OR IGNITION TURNED 2. Loose or worn generator 2. Adjust or replace generator drive belt.
OFF. drive belt.
3. Charging system output 3. T e s t a n d repair charging s y s t e m , refer to G r o u p 8 A .
too low.
4. Battery has insufficient charge. 4. Test battery state-of-charge, refer to Group 8 A .
5. Battery is sulfated or shorted. 5. Load test battery, refer to G r o u p 8A.
6. Poor lighting circuit Z 1 - g r o u n d . 6. T e s t for voltage drop across Z1-ground locations,
refer to Group 8 W .
7. Both fog lamp bulbs 7. Replace both lamp bulbs.
defective.
FOG LAMP 1. Charging system output 1. Test a n d repair charging system, refer to Group 8A.
BULBS BURN OUT too high.
FREQUENTLY. 2. Loose or corroded terminals 2. Inspect a n d repair all connectors a n d splices, refer t o
or splices in circuit. G r o u p 8W.
FOG LAMPS ARE DIM 1. Charging system output 1. Test a n d repair charging s y s t e m , refer to Group 8 A .
WITH ENGINE too low.
RUNNING ABOVE IDLE. 2. Poor f o g lamp circuit 2. T e s t voltage d r o p across Z 1 - g r o u n d , refer to G r o u p 8 W .
ground.
3. High resistance in f o g 3. T e s t a m p e r a g e d r a w of f o g lamp circuit.
lamp circuit.
4. Both f o g lamp bulbs 4. Replace both fog lamp bulbs.
defective.
FOG LAMPS FLASH 1. Poor f o g lamp 1. Repair circuit g r o u n d , refer to Group 8 W .

RANDOMLY. circuit g r o u n d .
2. High resistance in f o g 2. T e s t a m p e r a g e d r a w of f o g lamp circuit.
lamp circuit.
3. Faulty fog lamp switch 3. Replace f o g lamp switch.
circuit breaker.
4. Loose or corroded terminals 4. Repair connector terminals or splices, refer to Group 8 W .
or splices in circuit.
FOG LAMPS DO 1. Blown fuse for f o g lamps. 1. Replace fuse, refer to group 8 W .
NOT ILLUMINATE.
2. No ground at fog lamps. 2. Repair circuit g r o u n d , refer to Group 8 W .
3. Faulty f o g lamp switch.
3. Replace f o g lamp s w i t c h .
4. Broken connector terminal
or wire splice in f o g 4. Repair connector terminal or wire splices.
lamp circuit.
J958L-12
HEADLAMP ALIGNMENT
INDEX
page page
GENERAL INFORMATION HEADLAMP ADJUSTMENT 6

HEADLAMP ALIGNMENT 5 HEADLAMP ALIGNMENT PREPARATION 5
FOG LAMP ALIGNMENT 6 HEADLAMP ALIGNMENT 7
GENERAL INFORMATION (2) Correct defective components that could hinder

proper headlamp alignment.
HEADLAMP ALIGNMENT (3) Verify proper tire inflation.
Headlamps can be aligned using the screen method pro (4) Clean headlamp lenses.
vided in this section. Alignment Tool C-4466-A or equiva (5) Verify that luggage area is not heavily loaded.
lent can also be used. Eefer to instructions provided with (6) Fuel tank' should be FULL. Add 2.94 kg (6.5
the tool for proper procedures. The preferred headlamp lbs.) of weight over the fuel tank for each estimated
alignment setting is 0 for the left/right adjustment gallon of missing fuel.
and 1" down for the up/down adjustment.
ALIGNMENT SCREEN PREPARATION
(1) Position vehicle on a level surface perpendicu
SERVICE PROCEDURES lar to a flat wall 7.62 meters (25 ft) away from front
of headlamp lens (Fig. 1).
HEADLAMP ALIGNMENT PREPARATION (2) I f necessary, tape a line on the floor 7.62
(1) Verify headlamp dimmer switch and high beam meters (25 ft) away from and parallel to the wall.
indicator operation.
CENTER OF LOW BEAM HOT FLOOR T O

VEHICLE T O SPOT AREA CENTER OF
CENTER OF , HEADLAMP
HEADLAMP LENS
LENS
VEHICLE
CENTERLINE
FRONT OF
HEADLAMP 938L-61
Fig. 1 Headlamp Alignment Screen—Typical

8L - § LAMPS ii
(3) Up 1.27 meters (5 feet) from the floor, tape a
LEFT AND RIGHT
line on the wall at the centerline of the vehicle. Sight ADJUSTMENT SCREW
along the centerline of the vehicle (from rear of vehi
cle forward) to verify accuracy of the line placement.
(4) Rock vehicle side-to-side three times to allow
suspension to stabilize.
(5) Jounce front suspension three times by pushing
downward on front bumper and releasing.
(6) Measure the distance from the center of head
lamp lens to the floor. Transfer measurement to the
alignment screen (with tape). Use this line for
up/down adjustment reference.
(7) Measure distance from the centerline of the vehicle
to the center of each headlamp being aligned. Transfer UP AND DOWN J958L-23
measurements to screen (with tape) to each side of vehicle ADJUSTMENT SCREW
centerline. Use these lines for left/right adjustment refer Fig. 2 Aero Headlamp Alignment
ence.
for the left/right adjustment. The high beam pattern
HEADLAMP ADJUSTMENT should be correct when the low beams are aligned properly.
A properly aimed low beam headlamp will project top To adjust headlamp aim, rotate alignment screws (Fig. 2)
edge of high intensity pattern on screen from 50 mm (2 in.) to achieve the specified high intensity pattern.
above to 50 mm (2 in.) below headlamp centerline. The
side-to-side outboard edge of high intensity pattern should FOG LAMP ALIGNMENT
be from 50 mm (2 in.) left to 50 mm (2 in.) right of head Prepare an alignment screen. Refer to Alignment
lamp centerline (Fig. 1). The preferred headlamp align Screen Preparation paragraph in this section. A prop
ment is 1" down for the up/down adjustment and § erly aligned fog lamp will project a pattern on the
alignment screen 100 mm (4 in.) below the fog lamp
centerline and straight ahead (Fig. 3).
CENTER OF HIGH-INTENSITY FLOOR T O

VEHICLE TO AREA CENTER O F
CENTER O F F O G LAMP
F O G LAMP LENS
LENS
VEHICLE
CENTERLINE
FRONT O F
F O G LAMP 938L-26
Fig. 3 Fog Lamp Alignment —Typical

BR LAMPS 8L - 7
SPECIAL TOOLS
HEADLAMP ALIGNMENT
Headlamp Aiming Kit C-4466-A

8L - 8 LAMPS BR
LAMP B U L B S E R V I C E
INDEX
page page
REMOVAL AND INSTALLATION PARK AND TURN SIGNAL LAMP 8

CARGO LAMP BULB 9 REAR IDENTIFICATION (ID) LAMP BULBS 10
CENTER HIGH MOUNTED STOP LAMP ROOF CLEARANCE LAMP BULB 9
(CHMSL) BULB 9 SIDE IDENTIFICATION (ID) LAMP BULBS 9
DOME LAMP BULB 10 TAIL, STOP, TURN SIGNAL AND BACK-UP
FOG LAMP 8 LAMP BULB—CAB CHASSIS 9
FRONT SIDE MARKER LAMP BULB 9 TAIL, STOP, TURN SIGNAL AND BACK-UP
HEADLAMP 8 LAMP BULB—PICKUP 9
LICENSE PLATE LAMP BULB 10 UNDERHOOD LAMP BULB 10
OVERHEAD CONSOLE READING LAMP BULB . 10
REMOVAL AND INSTALLATION BULB BULB

SOCKET RETAINING
RING
HEADLAMP
On driver side and on vehicles with dual batteries, ELECTRICAL
the headlamp assembly must be removed to service CONNECTOR.
the headlamp bulb.
R E M O V A L
(1) Release hood latch and open hood.
(2) To remove headlamp assembly on drivers side LENS/ UNLOCK
918L-34
or passenger side when equipped with dual batteries, REFLECTOR
refer to Headlamp Removal paragraph of Exterior
Fig. 1 Headlamp Bulb Removal
Lamps section.
(3) Disengage wire connector from headlamp bulb. INSTALLATION
(4) Remove retaining ring holding bulb to head
lamp (Fig. 1). CAUTION: Do not touch the bulb glass with fin
(5) Pull bulb from headlamp. gers or other oily surfaces. Reduced bulb life will
result.
INSTALLATION
(1) Position bulb assembly in lamp and rotate
CAUTION: Do not touch the bulb glass with fin clockwise.
gers or other oily surfaces. Reduced bulb life will (2) Connect fog lamp harness connector.
result.
PARI AND TURN SIGNAL LAWIP
(1) Position bulb in headlamp.
(2) Install retaining ring holding bulb to headlamp REMOVAL
(Fig. 1). (1) Remove park and turn signal lamp.
(2) Rotate bulb socket 1/4 turn counterclockwise
(3) Connect wire connector to headlamp bulb. and pull turn signal lamp socket from back of lamp.
(3) Pull park and turn signal lamp bulb from
F 0 i LAMP socket.
REMOVAL
(1) Disengage fog lamp harness connector. INSTALLATION
(2) Rotate bulb assembly counterclockwise and (1) Install park and turn signal lamp bulb i n
pull from lamp to separate (Fig. 2). socket.
(2) Install park and turn signal lamp socket into
back of lamp.
(3) Install park/turn signal lamp.
BR LAMPS 8L-9
SIDE IDENTIFICATION (ID) LAMP BULBS
The bulbs in the side ID lamps can not be
replaced. I f a bulb should fail, the entire lamp would
require replacement. Refer to the Side Identification
Lamp Removal/Installation procedure i n this group.
TAIL, STOP, TURN SIGNAL AND BACK-UP LAMP

BULB—PICKUP
REMOVAL
(1) Remove screws from tail lamp (Fig. 3).
(2) Grasp lamp, firmly pull lamp rearward to dis
engage retaining studs.
(3) Remove socket from tail lamp.
(4) Separate tail lamp from cargo box.
(5) Pull bulb from socket.
Fig. 2 Fog Lamp
INSTALLATION
FRONT SIDE MARKER LAMP BULB
(1) Install bulb in socket.
REMOVAL (2) Install socket in tail lamp.
(1) Remove park and turn signal lamp. (3) Position tail lamp in cargo box, engage retain
(2) Remove side marker lamp socket from back of ing studs and install screws (Fig. 3).
lamp.
(3) Pull side marker lamp bulb from socket.
INSTALLATION
(1) Install side marker lamp bulb in socket.
(2) Install side marker lamp socket into back of
lamp.
(3) Install park/turn signal lamp.
ROOF CLEARANCE LAMP BULB

For bulb replacement refer roof clearance lamp
removal/installation procedure.
CENTER HIGH MOUNTED STOP LAMP (CHMSL)

BULB
REMOVAL
(1) Remove the CHMSL from the roof panel.
(2) Rotate sockets 1/4 turn clockwise and remove
from lamp. (The center bulbs light the stoplamp and
the outside bulbs light the cargo lamp.) RETAINING
STUDS J948L-6
(3) Pull bulb from socket.
Fig. 3 Tail, Stop, Turn Signal and Back-up Lamp
fffSTALLATIOff
Bulb
(1) Push bulb into socket.
(2) Position socket in lamp an rotate socket 1/4 TAIL, STOP, TURN SIGNAL AND BACK-UP LAMP
turn counterclockwise. BULB—CAB CHASSIS
(3) Install the CHMSL.
REMOVAL
CARGO LAMP BULB (1) Remove screws holding tail lamp lens to lamp
The cargo lamp bulb is incorporated in the CHMSL body.
assembly, refer to the CHMSL bulb removal and (2) Separate lens from lamp.
installation procedure for bulb replacement. (3) Remove bulb from socket.
81 - 1 0 LAMPS — - _ _ _ _ r a = s ^ ^ mm

INSTALLATION INSTALLATION
(1) Install bulb in socket. (1) Install bulb in lamp.
(2) Install lamp lens. (2) Position lens on lamp and snap into place.
iEAR IDENTIFICATION (ID) LAMP BULBS OVERHEAD CONSOLE READING LAMP BULB
The bulbs in the rear ID lamps can not be
replaced. I f a bulb should fail, the entire lamp would REMOVAL
require replacement. (1) Insert a flat blade screwdriver in slot at front
of lens (Fig. 4).
LICENSE PLATE LAMP BULB (2) Rotate the screwdriver until lens snaps out of
the housing.
REMOVAL (3) Remove lens from housing.
(1) Remove license plate lamp lens. (4) Remove bulb from terminals.
(2) Pull bulb from license plate lamp.
INSTALLATION
INSTALLATION (1) Insert bulb into reading lamp terminals.
(1) Install bulb in license plate lamp. (2) Replace lens by holding lens level and pushing
(2) Install license plate lamp lens. rearward into housing.
(3) Push lens up to snap into housing.
UNDERHOOD LAMP BULB
REMOVAL
(1) Disconnect the wire harness connector from the
underhood lamp.
(2) Rotate the bulb counterclock-wise. Remove i t
from the lamp socket.
fffSTALLATIOM
(1) Insert the replacement bulb in the lamp base
socket. Rotate i t clockwise.
(2) Connect the wire harness connector to the
lamp.
DOME LAMP BULB CONSOLE

J9523-88-
REMOVAL
(1) Remove dome lamp lens. Fig. 4 Overhead Console Reading Lamp Bulb
(2) Pull bulb from lamp. Removal
BR
L A M P SERVICE
INDEX
page page
REMOVAL AND INSTALLATION PARK, TURN SIGNAL AND SIDE MARKER

CARGO LAMP . . . . 12 LAMP ... . . . . 11
CENTER HIGH MOUNTED STOP LAMP REAR IDENTIFICATION (ID) LAMPS 13
(CHMSL) . 12 ROOF CLEARANCE LAMP 12
DOME LAMP 14 SIDE IDENTIFICATION (ID) LAMPS 12
FOG LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 TAIL, STOP, TURN SIGNAL AND BACK-UP
HEADLAMP 11 LAMPS—CHASSIS CAB . . . . . . . . . . . . . 13
LICENSE PLATE LAMP 14 TAIL, STOP, TURN SIGNAL AND BACK-UP
OVERHEAD CONSOLE READING LAMP . . . . . . 14 LAMPS—PICKUP 13
R E M O V A L AND I N S T A L L A T I O N
HEADLAMP
HEADLAMP
SOCKET
REMOVAL
(1) Release hood latch and open hood.
(2) Remove park and turn signal lamp.
(3) Remove screws holding top of headlamp mod
ule to radiator closure panel (Fig. 1).
(4) From behind front bumper, remove screws
holding bottom of headlamp module to radiator clo
sure panel.
(5) Separate headlamp module from radiator clo
sure panel.
(6) Disengage wire connector from headlamp bulb.
(7) Separate headlamp module from vehicle.
INSTALLATION
(1) I f removed, install headlamp bulb.
(2) Connect headlamp bulb wire connector. TURN AND PARK
(3) Position headlamp in radiator closure panel. LAMP HOUSING
(4) From behind front bumper, install the screws
holding bottom of headlamp module to radiator clo Fig. 1 Headlamp Removal/Installation
sure panel.
(5) Install the screws holding top of headlamp INSTALLATION
module to radiator closure panel (Fig. 1). (1) Position fog lamp i n bumper.
(6) Install park and turn signal lamp. (2) Install fog lamp to bumper attaching nuts.
(7) Close hood. (3) Connect fog lamp harness connector.
(4) Check for proper operation and beam align
FOG LAMP ment.
The fog lamps are serviced from the rearward side
PARK, TURN SIGNAL AND SIDE MARKER LAMP
of the front bumper.
1EMOVAI REMOVAL
(1) Disengage fog lamp harness connector. (1) Remove screw holding park lamp to headlamj
(2) Remove fog lamp to bumper attaching nuts module.
(Fig. 2). (2) Disengage clip holding park lamp to headlam
(3) Separate fog lamp from bumper. module.
(3) Separate park lamp headlamp module.
_ ic LMivirs BR
Fig. 2 Fog Lamp Fig. 3 Roof Clearance Lamps

(4) Remove park and turn signal socket from back
of lamp.
( 5 ) Remove side marker socket from back of lamp.
(6) Separate park and turn signal lamp from vehi
cle.
INSTALLATION
Reverse the removal procedure.
ROOF CLEARANCE LAMP
REMOVAL
(1) Remove screws holding clearance lamp lens to
roof panel (Fig. 3).
(2) Rotate socket 1/4 turn counterclockwise and
separate socket from lamp.
INSTALLATION -
(1) Install socket in lamp and rotate socket 1/4
turn clockwise.
(2) Position clearance lamp on roof.
(3) Install screws holding clearance lamp lens to SCREW J948L-4X
roof panel. Tighten to 1 N-m (13 in. lbs.).
Fig. 4 Center High Mounted Stop Lamp
CENTER HIGH MOUNTED STOP LAMP (CHMSL) CARGO LAMP
The cargo lamp is incorporated into the CHMSL, i f
REMOVAL equipped. Refer to Center High Mounted Stop Lamp
(1) Remove screws holding CHMSL to roof panel paragraph for service procedures.
(Fig. 4).
(2) Separate CHMSL from roof. SIDE IDENTIFICATION (ID) LAMPS
(3) Disengage wire connector from body wire har-
iess. REMOVAL
(4) Separate CHMSL from vehicle. (1) Using a flat blade screw driver, disengage clips
holding ID lamp to retainer (Fig. 5).
NSTALLATION (2) Separate ID lamp from retainer.
(1) Position lamp at cab roof and connect wire con- (3) Disengage lamp bulb socket from lamp.
ector. (4) Remove screws holding lamp retainer to rear
(2) Install screws holding CHMSL to roof panel, fender.
ighten securely. (5) Separate retainer from rear fender.
BR LAMPS 8L - 1 3
INSTALLATION
(1) Install socket in tail lamp.
(2) Position tail lamp in cargo box, engage retain
ing studs and install screws.
(3) Close tailgate.
TAIL, STOP, TURN SIGNAL AND BACK-UP

LAMPS—CHASSIS CAB
REMOVAL
( 1 ) Remove nuts * holding tail lamp to mounting
bracket (Fig. 7 ) .
(2) Disengage tail lamp wire connector from body
wire harness.
(3) Separate tail lamp[ from vehicle.
Fig. 5 Side Identification Lamps

INSTALLATION
TAIL, STOP, TURN SIGNAL AND BACK-UP LICENCE

PLATE BRACKET
LAMPS—PICKUP
REMOVAL
(1) Release tailgate latch and open tailgate.
(2) Remove screws holding tail lamp to cargo box
(Fig. 6).
(3) Grasp lamp, firmly pull lamp rearward to dis
engage retaining studs.
(4) Remove socket from tail lamp.
(5) Separate tail lamp from cargo box.
(6) Separate tail lamp from vehicle.
BRACKET * J948L-9
Fig. 7 Tail, Stop, Turn Signal and Back-up Lamps—

Cab Chassis
INSTALLATION
REAR IDENTIFICATION (ID) LAMPS
REMOVAL
Individual lamps may be replaced by removing the
lamp from the light bar.
( 1 ) Remove screws holding rear ID lamps to tail
gate (Fig. 8).
(2) Separate ID lamps from tailgate.
(3) Disengage ID lamp wire connector from body
wire harness.
RETAINING (4) Separate ID lamp from vehicle.
STUDS J948L-6
INSTALLATION
Fig. 6 Tail Lamp Assembly Reverse the removal procedure.
8L - 14 LAMPS BR
LAMP
BUMPER PANEL
SCREW
SCREW
TAILGATE BUMPER
MARKER LAMPS J948L-10 LICENSE
PLATE
LAMP J948L-7
Fig. 8 Rear identification Lamps
LICENSE PLATE LAMP Fig. 9 License Plate Lamp Panel
(4) Place dome lamp lens on dome lamp and snap
REMOVAL
(1) Remove screws holding license plate panel to into place.
cargo box.
(2) Disengage license plate lamp wire connector
from body wire harness (Fig. 9).
(3) Separate license plate lamp from vehicle.
INSTALLATION
DOME LAMP
REMOVAL
(1) Using a suitable flat blade screw driver, pry
dome lamp lens from dome lamp.
(2) Remove screws holding dome lamp to roof rein
forcement (Fig. 10).
(3) Separate dome lamp from roof.
(4) Disengage dome lamp wire connector from body DOME LAMP
wire harness. HOUSING
(5) Separate dome lamp from vehicle.
INSTALLATION DOME LAMP
(1) Position dome lamp at headliner. LENS J948L-5
(2) Connect dome lamp wire connector to body
wire harness. Fig. 10 Dome Lamp
(3) Install screws holding dome lamp to roof rein
OVERHEAD CONSOLE READING LAMP
forcement (Fig. 10).
To service overhead console refer to Group 8C,
Overhead Console.
BR LAMPS 8L - 1 5
LAMP SYSTEMS
INDEX
page

DAYTIME RUNNING LAMP MODULE 15
DAYTIME RUNNING LAMP MODULE
REMOVAL
(1) Release hood latch an open hood.
(2) Disconnect wire connector from DRLM (Fig. 1).
(3) Remove screw holding DRLR to engine com
partment dash panel.
(4) Separate DRLM from dash panel.
INSTALLATION
Fig. 1 Daytime Running Lamp Module (DRLM)

BULB APPLICATION
1NDEI
page page
G E N E R A L INFORMATION INTERIOR LAMPS . . . 16

GENERAL INFORMATION . . . . . . . . . . . . . 16
SPECIFICATIONS
EXTERIOR LAMPS 16
GENERAL I N F O R M A T I O N be replaced. The Mechanical Instrument Cluster

(MIC) uses PC194 bulbs for illumination.
GENERAL INFORMATION
The following Bulb Application Tables lists the LAMP BULB
lamp title on the left side of the column and trade A/C Heater Control .... . .158
number or part number on the right. Ash Receiver 161
Cigar Lighter 161
CAUTION: Do not use bulbs that have a higher Headlamp Switch .158
candle power than the bulb listed in the Bulb Appli Heater Control . .158
cation Table. Damage to lamp can result. Do not Instrument Cluster . . . . . . . . . . . . . . . . . . . . .PC194
touch halogen bulbs with fingers or other oily sur Radio ASC
faces. Bulb life will be reduced.
INDICATOR LAMPS
Service procedures for most of the lamps in the instru
ment panel, instrument cluster and switches are located
SPECIFICATIONS
in Group 8E, Instrument Panel and Gauges.
EXTERIOR LAMPS
LAMP BULB
LAMP BULB Airbag High Line PC194
Back-up . .3157 Airbag low Line PC74
Cargo . . . . . . .921 Anti-lock Brake . .PC74
Center High Mounted Stop . .921 Battery Voltage PC194
Clearance .194 Brake Warning PC194
Headlamp . .9004 Check Engine. .PC74
License Plate .1155 Engine Oil Pressure. .PC74
License Plate—Step Bumper .168 Four Wheel Drive . PC194
Park/Turn Signal 3157NA High Beam .PC194
Snow Plow Control . .161 Low Fuel PC194
Tail/Stop/Turn Signal 3157 Low Washer Fluid PC74
Tail/Stop/Cab—Chassis 1157 Maintenance Required PC74
Underhood 105 Message Center PC 194
Seat Belt .PC74
INTERIOR LAMPS Turn Signal . . . . . . . . . . .PC194
Upshift PC74
DIMMER CONTROLLED LAMPS
Service procedures for most of the lamps in the NON-DIMMING LAMPS
instrument panel, Instrument cluster and switches Some components have lamps that can only be ser
are located in Group 8E, Instrument Panel and viced by a Authorized Service Center (ASC) after the
Gauges. Some components have lamps that can only component is removed from the vehicle. Contact local
be serviced by a Authorized Service Center (ASC) dealer for location of nearest ASC.
after the component is removed from the vehicle.
Contact local dealer for location of nearest ASC. LAMP BULB
When illumination goes out in the Electronic Instru Dome 1004
ment Cluster (EIC) the complete button module must Glove Compartment 1891
BR PASSIVE RESTRAINT SYSTEMS 8M -1
PASSIVE RESTRAINT SYSTEMS
CONTENTS
page page
GENERAL INFORMATION CLEAN-UP PROCEDURE 3

INTRODUCTION 1 REMOVAL AND INSTALLATION
DESCRIPTION AND OPERATION AIRBAG CONTROL MODULE 8
AIRBAG CONTROL MODULE 2 AIRBAG MODULE 4
AIRBAG MODULE 2 CLOCKSPRING 9
CLOCKSPRING 2 IMPACT SENSORS 5
IMPACT SENSORS 2 ADJUSTMENTS
DIAGNOSIS AND TESTING CLOCKSPRING CENTERING 10
AIRBAG SYSTEM 2
SERVICE PROCEDURES
AIRBAG SYSTEM 3
G E N E R A L INFORMATION AND EXTREMELY FLAMMABLE. CONTACT WITH

ACID, WATER, OR HEAVY METALS MAY PRODUCE
INTRODUCTION HARMFUL AND IRRITATING GASES (SODIUM
The driver's side airbag system is a standard HYDROXIDE IS FORMED IN THE PRESENCE OF
equipment safety device on this model. I t is designed MOISTURE) OR COMBUSTIBLE COMPOUNDS. D O
to protect the driver from serious injury caused by a NOT ATTEMPT TO DISMANTLE THE MODULE OR
frontal impact of the vehicle. To inspect this system, TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE,
refer to the Airbag System - Body Diagnostic Proce INCINERATE, OR BRING INTO CONTACT WITH
dures manual. I f the airbag module assembly is ELECTRICITY. DO NOT STORE AT TEMPERATURES
defective and non-deployed, refer to the Chrysler Cor EXCEEDING 93°C (200°F).
poration current parts return list in the Warranty • REPLACE AIRBAG SYSTEM COMPONENTS
Policies and Procedures manual for the proper han ONLY WITH PARTS SPECIFIED IN THE CHRYSLER
dling procedures. MOPAR PARTS CATALOG. SUBSTITUTE PARTS
Following are general descriptions of the major MAY APPEAR INTERCHANGEABLE, BUT INTERNAL
components in the airbag system. Refer to 8W-43 - DIFFERENCES MAY RESULT IN INFERIOR OCCU
Airbag System in Group 8W - Wiring Diagrams for PANT PROTECTION. THE FASTENERS, SCREWS,
complete circuit descriptions and diagrams. AND BOLTS ORIGINALLY USED FOR THE AIRBAG
SYSTEM COMPONENTS HAVE SPECIAL COATINGS
WARNING: AND ARE SPECIFICALLY DESIGNED FOR THE AIR-
• THIS SYSTEM IS A SENSITIVE, COMPLEX BAG SYSTEM.THEY MUST NEVER BE REPLACED
ELECTRO-MECHANICAL UNIT. BEFORE ATTEMPT WITH SUBSTITUTES. ANY TIME A NEW FASTENER
ING TO DIAGNOSE, REMOVE OR INSTALL THE AIR- IS NEEDED, REPLACE IT WITH THE CORRECT FAS
BAG SYSTEM OR RELATED STEERING WHEEL TENERS PROVIDED IN THE SERVICE PACKAGE OR
AND STEERING COLUMN COMPONENTS, YOU SPECIFIED IN THE CHRYSLER MOPAR PARTS CAT
MUST FIRST DISCONNECT AND ISOLATE THE BAT ALOG.
TERY NEGATIVE (GROUND) CABLE. THEN WAIT • WHEN A STEERING COLUMN HAS AN AIRBAG
TWO MINUTES FOR THE SYSTEM CAPACITOR TO MODULE ATTACHED, NEVER PLACE THE COLUMN
DISCHARGE BEFORE FURTHER SYSTEM SERVICE. ON THE FLOOR OR ANY OTHER SURFACE WITH
THIS IS THE ONLY SURE WAY TO DISABLE THE THE STEERING WHEEL OR AIRBAG MODULE FACE
AIRBAG SYSTEM. FAILURE TO DO THIS COULD DOWN.
RESULT IN ACCIDENTAL AIRBAG SYSTEM
DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
• THE AIRBAG MODULE INFLATOR ASSEMBLY
CONTAINS SODIUM AZIDE AND POTASSIUM
NITRATE. THESE MATERIALS ARE POISONOUS
81 - 2 PASSIVE RESTRAINT SYSTEMS „ _ BR
DESCRIPTION AND OPERATION CL0CISPRIN6

The clockspring is mounted on the steering column
AIRBAG MOiULE behind the steering wheel. I t is used to maintain a
The airbag module protective cover is the most vis continuous electrical circuit between the wiring har
ible part of the system. The module is mounted ness and the driver's side airbag module. This assem
directly to the steering wheel. Under the airbag mod bly consists of a flat, ribbon-like electrically
ule cover, the airbag cushion and its supporting com conductive tape that winds and unwinds with the
ponents are contained. The airbag module contains a steering wheel rotation.
housing to which the cushion and inflator are
attached and sealed. The airbag module cannot be AIRBAG CONTROL MOiULE
repaired, and must be replaced i f deployed or in any The Airbag Control Module (ACM) contains the
way damaged. safing sensor, and a microprocessor that monitors the
The inflator assembly is mounted to the back of airbag system to determine its readiness. I t also
the module. The inflator seals the hole in the airbag monitors the impact sensors to determine when the
cushion so i t can discharge the gas i t produces proper conditions exist to provide the electrical signal
directly into the cushion when supplied with the that deploys the airbag. The ACM contains On-Board
proper electrical signal. The protective cover is fitted Diagnostics (OBD), and will light the airbag warning
to the front of the airbag module and forms a deco lamp in the instrument cluster when a monitored
rative cover in the center of the steering wheel. Upon airbag system fault occurs.
airbag deployment, this cover will split horizontally. The ACM also contains an energy-storage capaci
tor. This capacitor stores enough electrical energy to
STORAGE deploy the airbag for up to two minutes following a
The airbag module must be stored in its original, battery disconnect or failure. The purpose of the
special container until used for service. Also, i t must capacitor is to provide airbag system protection in a
be stored in a clean, dry environment; away from severe secondary impact i f the initial impact has
sources of extreme heat, sparks, and high electrical damaged or disconnected the battery, but was not
energy. Always place or store the module on a surface severe enough to deploy the airbag.
with the trim cover facing up to minimize movement
in case of accidental deployment.
IMPACT SENSORS
The impact sensors provide verification of the AIRBAG SYSTEM
direction and severity of the impact. Three sensors A DRB scan tool is required for diagnosis of the
are used. One is called a sating sensor. It is located airbag system. Refer to the Airbag System - Body
inside the Airbag Control Module (ACM), which is Diagnostic Procedures manual for more information.
mounted to a bracket under the instrument panel, on (1) Disconnect and isolate the battery negative
the top of the floor pan transmission tunnel. The cable. I f the airbag system is undeployed, wait two
other two sensors are mounted on the inner fender minutes for the system capacitor to discharge before
extension panels behind the grille opening reinforce further service.
ment, on the left and right sides of the vehicle. The (2) Connect the DRB scan tool to the 16-way data
sensors are calibrated for the specific vehicle, and link connector. The connector is located under the
react to the severity and direction of the impact. lower left corner of the instrument panel behind the
The impact sensors are threshold sensitive steering column cover/knee blocker (Fig. 1).
switches that complete an electrical circuit when an (3) From the right side of the vehicle (away from
impact provides a sufficient deceleration force to the airbag module i n case of an accidental deploy
close the switch. The safing sensor is an accelerome- ment), turn the ignition switch to the On position.
ter that senses the rate of deceleration. The micro Exit the vehicle with the DRB. Use the latest version
processor in the ACM monitors the sensor signals. A of the proper DRB cartridge.
pre-programmed decision algorithm in the micropro (4) After checking that nobody is inside the vehi
cessor determines when the deceleration rate indi cle, reconnect the battery negative cable.
cates an impact that is severe enough to require (5) Using the DRB, read and record the active
airbag system protection. Diagnostic Trouble Code (DTC) data.
The impact sensors are available for service (6) Read and record any stored DTC data.
replacement. The safing sensor is only serviced as (7) Refer to the Airbag System - Body Diagnostic
part of the ACM. Procedures manual, i f any DTC is found in Step 5 or
Step 6.
BR PASSIVE RESTRAINT SYSTEMS 8M - 3
DIAGNOSIS mm TESTING (Continued)

In addition, the airbag system should be disarmed
whenever the steering wheel or steering column
requires service or removal. Failure to observe this
CONNECTOR warning could result in accidental airbag deployment
and possible personal injury. Refer to Group 19 -
Steering for additional service procedures on the
steering wheel and steering column.
DEPLOYED
Any vehicle which is to be returned to use after an
airbag system deployment, must have the airbag
module and clockspring replaced. These are one-time
components and cannot be reused. Other airbag sys
tem components are replaced as required by the
extent of damage.
CLEAN-UP PROCEDURE
Following an airbag system deployment, the vehi
cle interior will contain a powdery residue. This res
idue is primarily sodium bicarbonate (baking soda),
used as an airbag cushion lubricant. However, there
will also be traces of sodium hydroxide powder, a
Fig. 1 16-Way Data Link Connector - Typical chemical by-product of the generant used for airbag
system deployment. Since this powder can irritate
(8) Erase the stored DTC data, i f there are no
the skin, eyes, nose, or throat, be sure to wear safety
active fault codes. I f any problems remain, the stored
glasses, rubber gloves, and a long-sleeved shirt dur
DTC data will not erase.
ing cleanup (Fig. 2).
(9) With the ignition switch still in the On posi
tion, make sure nobody is in the vehicle.
(10) From the right side of the vehicle turn the
ignition switch to the Off position, and then back to
the On position. Observe the airbag warning lamp in
the instrument cluster. I t should light for six to eight
seconds -then go out. This indicates that the airbag
system is functioning normally.
NOTE: If the airbag warning lamp fails to light, or

Bights and stays on, there is a system malfunction.
Refer to the Airbag System - Body Diagnostic Pro
cedures manual to diagnose the problem.
SERVICE PROCEDURES
Fig. 2 Wear Safety Glasses and Rubber Gloves
AIRBAG SYSTEM
WARNING: IF YOU EXPERIENCE SKIN IRRITATION
UNDEPLOYED DURING CLEANUP, RUN COOL WATER OVER THE
At no time should any source of electricity be per AFFECTED AREA. ALSO, IF YOU EXPERIENCE
mitted near the inflator on the back of the airbag IRRITATION OF THE NOSE OR THROAT, EXIT THE
module. When carrying an undeployed airbag mod VEHICLE FOR FRESH AIR UNTIL THE IRRITATION
ule, the trim cover should be pointed away from the CEASES. IF IRRITATION CONTINUES, SEE A PHYSI
body to minimize injury i n the event of accidental CIAN.
deployment. I f the module is placed on a bench or
any other surface, the plastic trim cover should be Begin clean-up by applying tape over the airbag
face up to minimize movement in the event of an exhaust vent so that no more powder will find its
accidental deployment. way into the vehicle interior (Fig. 3). Then remove
the airbag module from the vehicle.
8M - 4 PASSIVE RESTRAINT SYSTEMS - BR

ING TO DIAGNOSE, REMOVE OR INSTALL THE AIR-
BAG SYSTEM OR RELATED STEERING WHEEL
AND STEERING COLUMN COMPONENTS YOU
MUST FIRST DISCONNECT AND ISOLATE THE BAT
TERY NEGATIVE (GROUND) CABLE- THEN WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR TO
DISCHARGE BEFORE FURTHER SYSTEM SERVICE.
THIS IS THE ONLY SURE WAY TO DISABLE THE
AIRBAG SYSTEM. FAILURE TO DO THIS COULD
RESULT IN ACCIDENTAL AIRBAG SYSTEM
DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
• WHEN REMOVING A DEPLOYED AIRBAG MOD
ULE, RUBBER GLOVES, EYE PROTECTION, AND A
LONG-SLEEVED SHIRT SHOULD BE WORN. THERE
MAY BE DEPOSITS ON THE AIRBAG MODULE AND
OTHER INTERIOR SURFACES. IN LARGE DOSES,
Fig. 3 Airbag Exhaust Went Seating THESE DEPOSITS MAY CAUSE IRRITATION TO THE
SKIN AND EYES.
Use a vacuum cleaner to remove any residual pow
der from the vehicle interior. Clean from outside the (1) Disconnect and isolate the battery negative
vehicle and work your way inside, so that you avoid cable. I f the airbag module is undeployed, wait two
kneeling or sitting on an uncleaned area. minutes for the system capacitor to discharge before
Be sure to vacuum the heater and air conditioning further service.
outlets as well (Fig. 4). Run the heater and air con (2) From the underside of the steering wheel,
ditioning blower on the lowest speed setting and vac remove the speed control switch or trim bar mount
uum any powder expelled from the outlets. You may ing screws (Fig. 5).
need to vacuum the interior of the vehicle a second
time to recover all of the powder.
Fig. 5 Speed Control Switch Remove/Install
Fig. 4 Vacuum Heater and A/C Outlets

(3) Pull the switches or trim bar from the steering
wheel. I f equipped with speed control, unplug the
Place the deployed airbag module in your vehicular wiring connector from the switch (Fig. 6).
scrap pile. (4) Remove the four nuts attaching the airbag
module to the steering wheel (Fig. 7).
REMOVAL AND INSTALLATION (5) Remove the airbag module from the steering
wheel.
AIRBAG MODULE (6) Unplug the electrical connector from the airbag
module.
WARNING: (7) When installing, connect the clockspring wiring
• THIS SYSTEM IS A SENSITIVE, COMPLEX connector to the module by pressing straight in on
ELECTRO-MECHANICAL UNIT. BEFORE ATTEMPT- the connector. The connector should latch securely
BR PASSIVE RESTRAINT SYSTEMS 8M - 1
minutes for the system capacitor to discharge before

further service.
(2) Remove the plastic retainers holding the rub
ber air dam to the radiator support on the driver's
side.
(3) Working through the air dam opening, remove
the three screws holding the sensor to the front
wheelhouse extension (Fig. 8).
N
* SPEED CONTROL
SERVO
SPfED CONTROL
SWITCHES J948H-8
Fig. 6 Speed Control Switch Connector Remove/Install
LEFT IMPACT
SENSOR
J948M-4
Fig. 8 Left Impact Sensor Remove/Install

(4) Unplug the wiring connector from the sensor
and remove the sensor (Fig. 9).
NOTE: Do not remove the tape holding the sensor

wiring harness to the connector.
J948G-2
SENSOR
CONNECTOR
Fig. 7 Airbag Module Remove/Install
beneath the module connector locking clip arms to
assure positive connection.
(8) Install the four airbag module mounting nuts
and tighten to 9 to 11 N-m (80 to 100 in. lbs.).
(9) Install the speed control switch or trim bar, as
equipped.
(10) Do not connect the battery negative cable at
this time. See Airbag System in Diagnosis and Test
ing for the proper procedures.
IMPACT SENSORS
J948M-8
LEFT SIDE
¥-8 AND ¥-8 ENGINE Fig. 9 Impact Sensor Connector - Typical

(1) Disconnect and isolate the battery negative (5) To install, connect the sensor wiring lead to the
cable. I f the airbag module is undeployed, wait two impact sensor.
81 - 6 PASSIVE RESTRAINT SYSTEMS BR
(6) Mount the sensor (arrow pointed forward) (4) Remove the battery from the vehicle.
using the three screws provided with the new sensor. (5) From under the left front wheel opening,
Tighten screws to 4.5 - 5.6 N-m (40' -50 in. lbs.). remove the two forward battery tray nuts (Fig. 12).
(7) Install the rubber air dam to the left radiator
UNDERSIDE OF
support.
LEFT FRONT
(8) Do not connect the battery negative cable at WHEEL O P E N I N G
V-10 AND DIESEL ENGINE

cable. I f the airbag module is undeployed, wait two
further service.
(2) Remove the two battery holddown bolts (Fig. 10).
J948B-4
Fig. 12 Forward Battery Tray Nuts

(6) Remove the two nuts and two bolts holding the
battery tray to the vehicle (Fig. 13).
J948B-2 REMOVE 2
BATTERY TRAY
BOLTS
Fig. 10 Battery Holddown
(3) I f equipped, pull up on the battery heat shield
to remove i t (Fig. 11).
REMOVE 2 NUTS
Fig. 13 Battery Tray Mounting
BATTERY HEAT SHIELD ' ' J948S-3

Fig. 11 Battery Heat Shield
BR PASSIVE RESTRAINT -SYSTEMS 8M - 7
(7) Lift the battery tray up far enough for access to (11) Unplug the connector from the impact sensor
the speed control servo electrical connector (Fig. 14). and remove the sensor (Fig. 16).
SPEED CONTROL
BATTERY TRAY
SERVO
SENSOR
CONNECTOR
J948M-8
SERVO Fig. 16 Impact Sensor Connector - Typical

' MOUNTING
J948H-7
NUTS (2) (12) To install, connect the sensor wiring lead to
the sensor.
Fig. 14 Speed Control Servo Mounting (13) Mount the sensor (arrow pointed forward)
(8) Unplug the electrical connector from the speed using the three screws provided with the new sensor.
control servo. Tighten the screws to 4.5 - 5.6 N-m (40 - 50 in. lbs.).
(9) Move the battery tray enough to access the (14) Plug the harness connector into the speed con
impact sensor. trol servo.
(10) Remove the three screws holding the impact (15) Install the battery tray. Tighten all battery
sensor to the front wheelhouse extension (Fig. 15). tray mounting hardware to 16 N-m (140 in. lbs.).
(16) Install the battery in the vehicle, making sure
* N
SPEED CONTROL that the battery is properly positioned in the battery
SERVO tray.
(17) I f equipped, install the battery heat shield.
(18) Install the battery holddown clamp, making
sure that i t is properly positioned on the battery, use
the holes across from each other. Tighten the hold-
down bolts to 4 N-m (35 in. lbs.).
RIGHT SIDE
V-6 AND ¥-8 ENGINE

further service.
FORWARD- (2) Remove the three screws holding the sensor to
LEFT IMPACT
SENSOR
the front wheelhouse extension (Fig. 17).
J948M-4 (3) Unplug the connector from the impact sensor
Fig. 15 Left Impact Sensor Remove/Install
81 - 8 PASSIVE RESTRAINT SYSTEMS BR
(4) To install, connect the sensor wiring lead from

the harness to the connector on the body of the sen
sor.
(5) Mount the sensor (arrow pointed forward)
using the three screws provided with new sensor.
Tighten screws to 4.5 - 5.6 N-m (40 - 50 in. lbs.).
this time. See Airbag System in Diagnosis and test
AIRBAG CONTROL MODULE
WARNING: THE ACM CONTAINS ONE OF THE

Fig. 17 Right Impact Sensor Remove/Install IMPACT SENSORS WHICH ENABLE THE SYSTEM
TO DEPLOY THE AIRBAG. TO AVOID ACCIDENTAL
NOTE: Do not remove the tape holding the sensor DEPLOYMENT, NEVER CONNECT THE ACM ELEC
wiring harness to the connector. TRICALLY TO THE SYSTEM UNLESS IT IS BOLTED
SENSOR TO THE VEHICLE. BEFORE BEGINNING ANY AIR-
BAG SYSTEM REMOVAL OR INSTALLATION PRO
CEDURES, DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE (GROUND) CABLE FROM THE
VEHICLE BATTERY. THEN WAIT TWO MINUTES
FOR THE SYSTEM CAPACITOR TO DISCHARGE
BEFORE FURTHER SYSTEM SERVICE. THIS IS THE
ONLY SURE WAY TO DISABLE THE AIRBAG SYS
TEM. FAILURE TO DO THIS COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT, AND POSSI
BLE PERSONAL INJURY.

cable. I f the airbag system is undeployed, wait two
further service.
(2) Remove the two screws and the ACM cover
Fig. 18 Impact Sensor Connector - Typical
from the bottom of the center console (Fig. 19).
(4) To install, connect the sensor wiring lead to the
sensor.
(5) Mount the sensor (arrow pointed forward)
using the three screws provided with the new sensor.
Tighten the screws to 4.5 - 5.6 N-m (40 - 50 in. lbs.).
¥-10 AND DIESEL ENGINE

further service.
(2) Remove the three screws holding the sensor to
the front wheelhouse extension (Fig. 17).
(3) Unplug the connector from the impact sensor
Fig. 19 ACM Cover Screws Remove/Install
BR PASSIVE RESTRAINT SYSTEMS 81 - S

(3) Remove, the four screws holding the ACM to UPPER SHROUD GROUND UPPER
the transmission tunnel (Fig. 20). .
L 1 j CONTROL I U—1
MODULE
J948M-2
Fig. 20 Airbag Control Module Remove/install

LOWER FIXED
(4) Disconnect the wiring at the ACM. SHROUD SHROUD J9119-22
(5) Remove the ACM.
(6) To install, position the ACM with the arrow Fig. 21 Steering Column Shrouds Remove/Install
pointing forward.
(7) Connect the wiring at the ACM, be certain that
both connectors are seated and the locking tabs are
engaged.
(8) Attach the ACM to the transmission tunnel
with the four screws. Tighten to 11.8 - 16.3 N-m (105
- 145 in. lbs.).
(9) Install the ACM cover.
this time. See Airbag System' in Diagnosis and Test
CLOCKSPRING
(1) Turn the steering wheel until the front wheels
are in the straight-ahead position before starting the
repair.
Fig. 22 Knee Blocker Remove/Install
cable. I f the airbag system is undeployed, wait two
minutes for the system capacitor to discharge before necessary. The clockspring cannot be repaired. I t
further service. must be replaced if faulty, or if the airbag system has
(3) Remove the airbag module as described in this been deployed.
group. (11) When installing, snap the clockspring onto the
(4) Remove -the steering wheel with a * steering steering column. I f the- clockspring is not properly
wheel puller (Special Tool C-3428B). positioned, see Clockspring Centering in this group
(5) Unplug the wiring for the horn switches. before Installing the steering wheel.
(6) Remove the lower steering column shroud to (12) Connect the clockspring wiring to the instru
gain access to the clockspring wiring (Fig. 21). ment panel wiring harness. Be certain that the wir
(7) Remove the lower fixed column shroud. ing locator clips are properly seated on the outside of
(8) Remove the knee blocker (Fig. 22). the wiring trough and that the locking tabs are
(9) Disconnect the two-way connector between the engaged.
clockspring and the instrument panel wiring harness (13) Install the knee blocker.
at the lower left corner of the instrument panel. (14) Re-install the steering column shrouds. Be
(10) To remove, lift the locating fingers of the certain that the airbag wire is inside the shrouds.
clockspring assembly from the steering column as
8M - 10 PASSIVE RESTRAINT SYSTEMS BR
(15) The front - wheels should still be • in the
straight-ahead position. Install the steering wheel
being certain to fit the flats on the hub of the steer
ing wheel with the formations on the inside of the
clockspring. Pull the horn wiring through the upper,
smaller hole in the steering wheel hub. Pull the air-
bag, and speed control wiring through the bottom,
larger hole in the steering wheel hub. Tighten the
steering wheel nut to 61 N-m (45 ft. lbs.). Be certain
not to pinch the wiring between the steering wheel
and the nut.
(16) Connect the horn switch wire, then the airbag
wire to the airbag module. To assure complete con
nection, the latching arms must be visibly on top of
the airbag wiring connector housing.
(17) Install the airbag module and tighten the
nuts to 9 to 11 N-m (80 to 100 in. lbs.).
ADJUSTMENTS
Fig. 23 Clockspring Auto-Locking Tabs
CLOCKSPRING CENTERING-,. " . (8) From the end of the clockwise travel, rotate the
I f the rotating tape within the clockspring is not rotor two and one-half turns counterclockwise. The
positioned properly in relation to the steering wheel horn wire should end up at the top, and the airbag
and the front wheels, the clockspring may fail during wire at the bottom.
use. The clockspring must be centered i f i t is not (9) The front wheels should still be in the straight-
known to be properly positioned, or i f the front ahead position. Install the steering wheel being sure
wheels were moved from the straight-ahead position to fit the flats on the hub of the steering wheel with
with the clockspring removed during any service pro the formations on the inside of the clockspring. Pull
cedure. the horn wiring through the upper, smaller hole in
(1) Turn the steering wheel until the front wheels the steering wheel hub. Pull the airbag and speed
are i n the straight-ahead position before starting the control wiring through the bottom, larger hole i n the
centering procedure. steering wheel hub. Tighten the steering .wheel nut
(2) Disconnect and isolate the battery negative to 61 N-m (45 ft. lbs.). Be certain not to pinch the
cable. I f the airbag system is undeployed, wait two wiring between the steering wheel and the nut.
minutes for the system capacitor to discharge before (10) Connect the horn switch wire, then the airbag
further service. wire to the airbag module. To assure complete con
(3) Remove the airbag module as described in this nection, the airbag module connector latching arms
group. . . . must be visibly on top of the airbag wiring connector
(4} Remove • the steering-wheel with -a steering insulator.
wheel puller (Special Tool C-3428B). (11) Install the airbag module, and tighten the
(5) Unplug the wiring for the horn switches. nuts to 9 to 11 N-m (80 to 100 in. lb.).
. (6) Depress the two plastic auto-locking tabs (Fig. (12) Do not connect the battery negative cable at
23). this time. See Airbag System in Diagnosis and Test
(7) Keeping the locking mechanism disengaged, ing for the proper procedures.
rotate the clockspring rotor clockwise to the end of
its travel. Do not apply excessive torque.
BR POWER LOCI SYSTEMS 8P - 1
POWER L O C K S Y S T E M S
CONTENTS
page page
GENERAL INFORMATION POWER LOCK SWITCH 1

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1 REMOVAL ANO INSTALLATION
OESCRiPTlON ANi OPERATION POWER LOCK MOTOR 3
POWER LOCK MOTOR 1 POWER LOCK SWITCH 2
POWER LOCK SWITCH . . . . . . . . . . . . . . . . . . . 1
OlAGNOSIS ANO TESTING
POWER LOCK MOTOR 2
G E N E R A L INFORMATION DIAGNOSIS AND TESTING
INTRODUCTION POWER LOCI SWITCH

Power door locks are optional factory-installed equip For circuit descriptions and diagrams, refer to 8W-61
ment on this model. All doors can be locked and - Power Door Locks in Group 8W - Wiring Diagrams.
unlocked electrically by operating the switch on either (1) Check the fuse in the fuseblock module. I f OK,
front door panel. The power door locks operate with bat go to Step 2. I f not OK, replace the faulty fuse.
tery power supplied independent of the ignition switch. (2) Check for battery voltage at the fuse in the
Following are general descriptions of the major fuseblock module. I f OK, go to Step 3. I f not OK,
components i n the power lock system. Refer to 8W-61 repair the open circuit as required.
- Power Door Locks in Group 8W - Wiring Diagrams (3) Remove the power lock switch from the trim
for complete circuit descriptions and diagrams. Refer panel as described in this group. Carefully separate
to the owner's manual for more information on the the multiple terminal block on the wiring harness
features and use of this system. from the switch body.
(4) Check for battery voltage at the fused B(+) cir
cuit cavity of the switch connector, i f OK, go to Step
5. i f not OK, repair the open circuit to the fuse in the
fuseblock module.
POWER LOCK SWITCH
(5) Test the switch continuity. See the Switch Conti
The power locks are controlled by a two-way switch
nuity chart to determine i f the continuity is correct in
mounted in a bezel on the trim panel of each front door.
the Off, Lock, and Unlock switch positions (Fig. 1). I f
The switch controls both the battery and ground feeds
OK, go to Step 6. I f not OK, replace the faulty switch.
to the power lock motors. The battery and ground feeds
are reversed between the Lock and Unlock switch posi
tions. The power lock switches cannot be repaired. I f
faulty, the entire switch must be replaced. SWITCH CONTINUITY
POSITION BETWEEN
POWER LOCK MOTOR O

2
© OFF
PINS 1 & 4
1 PINS 2 & 3
In the power lock system, the locks are actuated by
a reversible motor mounted within each door. The
UNLOCK PINS 1 & 4
motor direction is controlled by the battery and PINS3&5
(UP)
ground feeds from the power - lock switches. The
power lock motor cannot be repaired. I f faulty, the 3 LOCK PINS 2 6c 3
4
entire motor must be replaced. (DOWN) PINS 1 & 5
o
D -
PIN IDENTIFICATION
PIN SIDE OF SWITCH J958P-
Fig. 1 Switch Continuity

8P - 2 POWER LOCK SYSTEMS BR
NOTE: The right power lock switch gets its ground REMOVAL AND INSTALLATION
feed through the left power lock switch.
POWER LOCK SWITCH
(6) Check for continuity between both ground circuit (1) Disconnect and isolate the battery negative cable.
cavities of the left switch connector and a good ground. (2) Remove the two screws in the door pull cup
In each case, there should be continuity. I f OK, go to and remove the cup (Fig. 2).
Step 7. I f not OK, repair the open circuit(s) as required.
(7) With the left switch removed, check for continuity REMOVE 2 SCREWS
between both door lock switch output circuit cavities of

the right switch connector and a good ground. - There
should be no continuity. I f OK, go to Step 8. I f not OK,
repair the short circuit as required.
(8) Check for continuity between the door lock out
put (lock) circuit cavities of the right and left door
switch connectors. Repeat the check between the door
lock output (unlock) circuit cavities. In each case,
there should be continuity. I f OK, see the diagnosis J948S-2
for the Power Lock Motor in this group. I f not OK,
Fig. 2 Door Pull Cup Remove/Install - Typical
repair the open circuit(s) as required.
(3) Remove the power window and lock switches by
POWER LOCK MOTOR reaching through the door pull - cup opening and
Before you proceed with this diagnosis, confirm depressing the switch bezel rear retaining tab (Fig. 3).
proper power lock switch and switch circuit opera
tion. See Power Lock Switch in this group for the
diagnostic procedures. For circuit descriptions and
diagrams, refer to 8W-61 - Power Door Locks in
Group 8W - Wiring Diagrams.
(1) Check each power lock motor for correct opera
tion while moving the power lock switch to both the
Lock and Unlock positions. I f all lock motors are
inoperative, go to Step 2. I f one lock motor is inoper
ative, go to Step 3.
(2) I f all lock motors are inoperative, the problem
may be caused by one shorted motor. Disconnecting a Fig. 3 Switch Bezel Rear Retaining Tab -Typical
shorted motor will allow the good motors to operate. (4) Pull the rear of the switch bezel up and away
Disconnect each motor connector, one at a time, and from the door trim panel.
re-check both the lock and unlock functions while (5) Unplug the wiring connectors from the
operating the power lock switch. I f both motors are switches (Fig. 4).
still inoperative after the above test, repair the short
or open circuit between the power lock motors and
the right power lock switch as required. I f discon
necting one motor causes the other motors to become
functional, go to Step 3.
(3) Once it is determined which lock motor is inoper
ative, that motor can be tested as follows. Disconnect
the wire connector at the inoperative motor. Apply 12
volts to the motor terminals to check its operation in
one direction. Reverse the polarity to check the opera
tion in the other direction. I f OK, repair the short or
open circuit between the inoperative power lock motor
and the right power lock switch as required. I f not OK,
replace the faulty motor.
J V
TABS FRONT CLIP
Fig. 4 Door Switch Connectors - Typical
BR POWER LOCI SYSTEMS 8P - 3

Install the switch bezel to the door trim panel by
Inserting the front of the bezel into the trim panel
opening, then push down on the rear of the bezel
until the retaining tab snaps into place.
POWER LOCK MOTOR

(1) Raise the door window to its full up position.
(2) Disconnect and isolate the battery negative cable.
(3) Remove the power lock switch as described in
this group.
knob rearward to remove it from the switch stem
(Fig. 5).
Fig. 5 Power Mirror Switch Knob Remove/Install

the switch (Fig. 6).
NOTE: To aid in the removal of the trim panel, start

(7) Roll the door watershield away from the bot

tom of the inner door panel to allow access to the
power lock motor (Fig. 7).
(8) Remove the three screws holding the lock
motor and latch assembly to the door.
(9) Disconnect the latch linkage rods. Fig. 7 Power Lock Motor and Latch Remove/lnstait
(10) Pull the motor and latch out far enough to (11) Reverse the removal procedures to install.
unplug the electrical connector. Remove the motor Tighten the motor and latch screws to 10.5 N-m (95
and latch from the door. in. lbs.).
BR POWER SEAT SYSTEMS 8R -1
POWER SEAT S Y S T E M S
CONTENTS
page page
GENERAL INFORMATION POWER SEAT ADJUSTER/MOTORS 2

INTRODUCTION 1 POWER SEAT SWITCH 2
DESCRIPTION AND OPERATION POWER SEAT SYSTEM 1
CIRCUIT BREAKER 1 REMOVAL AND INSTALLATION
POWER SEAT ADJUSTER/MOTORS 1 POWER SEAT ADJUSTER/MOTORS 3
POWER SEAT SWITCH 1 POWER SEAT SWITCH 3
CIRCUIT BREAKER 2
G E N E R A L INFORMATION operated by pushing the center seat switch to the

Forward or Rearward position.
INTRODUCTION When a switch is actuated, battery feed and a
• A six-way driver's side power seat is an available ground path are applied through the switch contacts
factory-installed option for this model. The power to the motor(s). The motor(s) operate to move the
seat system receives battery feed through a fuse in seat i n the selected direction until the switch is
the power distribution center and a circuit breaker i n released, or until the travel limit of the power seat
the fuseblock module at all times. adjuster is reached. When the switch is moved i n the
Following are general descriptions of the major opposite direction, the battery feed and ground path
components In the power seat system. Refer to 8W-63 to the motor(s) are reversed through the switch con
- Power Seat in Group 8 W - Wiring Diagrams for tacts. This causes the motor to run in the opposite
complete circuit descriptions and diagrams. direction.
Each motor contains a self-resetting circuit breaker
to protect i t from overload. Consecutive or frequent
DESCRIPTION AND OPERATION resetting of the circuit breakers must not be allowed
to continue, or the motors may be damaged. Make
POWER SEAT SWITCH the necessary repairs.
The power seat can be adjusted in six different The power seat adjuster and motors cannot be
ways using the power seat switch. The switch is repaired, and are serviced only as a complete unit. I f
located on the lower outboard side of the seat cushion any component in this unit should fail, the entire
frame. Refer to the owner's manual for more informa assembly must be replaced.
tion on power seat switch functions and seat adjust
ing procedures. The individual switches cannot be CIRCUIT BREAKER
repaired. I f one switch fails, the entire switch module An automatic resetting circuit breaker i n the fuse-
must be replaced. block module Is used to' protect the power seat sys
tem circuit. The circuit breaker can protect the
POWER SEAT ADJUSTER/MOTORS system from a short circuit, or from an overload con
There are three reversible motors that operate the dition caused by an obstructed or stuck seat adjuster.
power seat adjuster. The motors are connected to The circuit breaker cannot be repaired. I f faulty, i t
worm-drive gearboxes that move the seat adjuster must be replaced.
through a combination of drive cables and screw-type
drive units.
The front and rear of a seat are operated by differ DIAGNOSIS AND TESTING
ent motors. They can be raised or lowered indepen
dently of each other. When the center seat switch is POWER SEAT SYSTEM
pushed to the Up or Down position, both the front For circuit descriptions and diagrams, refer to
and rear motors operate i n unison, moving the entire 8W-63 - Power Seat In Group 8 W - Wiring Diagrams.
seat up or down. The forward-rearward motor is Before any testing is attempted, the battery should
be fully-charged and all connections and pins cleaned
8H - 2 POWER SEAT SYSTEMS BR
SWITCH POSITION CONTINUITY BETW£i=ft
B-N, B-J, B-M, AFT/FORWARD-

OFF
B-E, B-L, B-K
VERTICAL UP A-E, A-M, B-N, B-J
VERTICAL D O W N A-J, A - N , B-M, B-E
HORIZONTAL FORWARD A-L, B-K
HORIZONTAL AFT A-K, B-L

DOWN
FRONT TILT UP A-M, B-N
FRONT TILT D O W N A - N , B-M

TERMINALS SHOWN AS VIEWED
REAR TILT UP A-F, B-J FROM REAR OF SWITCH
REAR TILT D O W N A - J , B-E

908R-4
Fig. 1 Power Seat Switch Continuity

and tightened to ensure proper continuity and (1) Check the circuit breaker in the fuseblock mod
grounds. ule. I f OK, go to Step 2. I f not OK, replace the faulty
With the dome lamp on, apply the switch in the circuit breaker.
direction of the failure. I f the dome lamp dims, the (2) Remove the switch as described in this group,
seat may be jamming. Check under the seat for bind and check for battery voltage at the fused B(+) circuit
ing or obstructions. I f the dome lamp does not dim, cavity of the switch connector. I f OK, go to Step 3. I f
proceed with the following component tests. not OK, repair the open circuit to the fuseblock mod
ule as required.
CIRCUIT BREAKER (3) Check for continuity between the ground cir
For circuit descriptions and diagrams, refer to cuit cavity of the switch connector and a good
8W-63 - Power Seat in Group 8W - Wiring Diagrams. ground. There should be continuity. I f OK, go to Step
(1) Locate the correct circuit breaker in the fuse- 4. I f not OK, repair the open circuit to ground as
block module. Pull out the circuit breaker slightly, required.
but be sure that the terminals still contact the termi (4) Test the power seat switch as described in this
nals i n the fuseblock module. group. I f the switch tests OK, replace the faulty
(2) Connect the negative lead of a 12-volt DC volt power seat adjuster/motors assembly.
meter to a good ground.
(3) With the voltmeter positive lead, check both POWER SEAT SWITCH
terminals of the circuit breaker for battery voltage. For circuit descriptions and diagrams, refer to
If only one terminal has battery voltage, the circuit 8W-63 - Power Seat i n Group 8W - Wiring Diagrams.
breaker is faulty and must be replaced. If neither ter To check the power seat switch:
minal , has battery voltage, repair the open circuit (1) Remove the power seat switch as described in
from the power distribution center as required. this group.
(2) Use an ohmmeter to test the continuity of the
POWER SEAT ADJUSTER/MOTORS switches in each position. See the Power Seat Switch
For circuit descriptions and diagrams, refer to Continuity chart (Fig. 1). I f OK, see the Power Seat
8W-63 - Power Seat in Group 8W - Wiring Diagrams. Adjuster/Motors diagnosis. I f not OK, replace the
Operate the power seat switch to move all three faulty switch module.
seat motors. The seat should move in all directions.
If one or more of the motors operate, see the diagno
sis for the Power Seat Switch in this group. I f no
motors operate, proceed as follows:
BR PQWEFt SEAT SYSTEMS 8R - 3
R i U p W A L AND INSTALLATION POWER SEAT ADJUSTER/MOTORS

POWER SEAT SWITCH cable.
(1) Disconnect and isolate the battery negative (2) Remove the three bolts attaching the seat
cable. frame to the floor pan.
(2) Remove the two screws holding the switch and (3) Remove the one nut from the stud locating the
bezel to. the seat cushion frame (Fig. 2). seat frame to the floor pan.
(4) Remove the two bolts holding the power seat to
the center seat section (Fig. 4) and (Fig. 5).
Fig. 2 Seat Switch and Bezel Remove/install

(3) Remove the two screws holding the switch to
the bezel.
(4) Pull the switch out from the seat far enough to
access the multiple terminal block. Carefully release
Fig. 4 Driver's Power Seat Remove
the locking tabs and separate the multiple terminal
block on the wiring harness from the switch body
(Fig. 3).
J948R-3
Fig. 8 Seat Switch Remove

Fig. 5 Center Seat Section Attachment
8R - 4 POWER SEAT SYSTEMS BR
R E M O V A L AND INSTALLATION {Continued)
(5) Unplug the power seat wire harness connector
located under the seat.
(6) Remove the driver's seat assembly from the
vehicle.
(7) Remove the four screws attaching the seat
adjuster to the seat cushion frame (Fig. 6). -
Tighten the seat mounting hardware as follows:
• Seat cushion frame to adjuster bolts - 25 N-m
(18 ft. lbs.)
• Seat adjuster to floor pan bolts - 29 N-m (20. ft.
lbs.)
• Seat adjuster to floor pan nut - 41 N-m (80 ft
lbs.)
• Center seat section bolts - 25 N-m (18 ft. lbs.).
Fig. 6 Power Seat Adjuster Remove

BR POWER WINDOW SYSTEMS 8S -1
POWER W I N D O W SYSTEMS
CONTENTS
page page
GENERAL INFORMATION POWER WINDOW MOTOR 3

INTRODUCTION 1 POWER WINDOW SWITCH 2
DESCRIPTION AND OPERATION POWER WINDOW SYSTEM 1
CIRCUIT BREAKER 1 REMOVAL AND INSTALLATION
POWER WINDOW MOTOR 1 POWER WINDOW MOTOR 3
POWER WINDOW SWITCH 1 POWER WINDOW SWITCH 3
CIRCUIT BREAKER 2
G E N E R A L INFORMATION CIRCUIT BREAKER

An automatic resetting circuit breaker in the fuseblock
INTRODUCTION module is used to protect the power window system circuit.
Power windows are available as factory-installed The circuit breaker can protect the system from a short cir
optional equipment on this model. The power windows cuit, or from an overload condition caused by an obstructed
operate only with the ignition switch in the On position. or stuck window glass or regulator. The circuit breaker
This group covers diagnosis and service of only the electri cannot be repaired. If faulty, it must be replaced.
cal components in the power window system. For service of
mechanical components, such as the regulator, lift plate or
window tracks, refer to Group 23 - Body Components. B i A G ^ O S i S Aiifci T E S T I N G
Following are general descriptions of the major
components in the power window system. Eefer to POWER WINDOW SYSTEM
8W-60 - Power Windows in Group 8W - Wiring Dia For circuit descriptions and diagrams, refer to 8W-60
grams for complete circuit descriptions and diagrams. - Power Windows in Group 8W - Wiring Diagrams.
A L L WINDOWS INOPERATIVE
DESCRIFMM im\s> mimmfmm (1) Check the circuit breaker in the fuseblock mod
ule, as described in this group. I f OK, go to Step 2. I f
POWER WINDOW SWITCH not OK, replace the faulty circuit breaker.
Both front door windows can be raised or lowered elec (2) Remove the left front door power window switch.
trically by operating the dual two-way switches on the Check for continuity between the ground circuit cavity of
driver's door trim panel. A single two-way switch on the the switch connector and a good ground. If OK, go to Step
passenger's door trim panel operates only the window on 3. If not OK, repair the circuit to ground as required.
the passenger's side. The power window switches cannot be (3) Turn the ignition switch to the On position.
repaired and, if faulty, must be replaced. Check for battery voltage at the fused ignition switch
output circuit cavity of the switch connector. I f OK,
POWER WINDOW MOTOR see the Power Window Switch diagnosis in this
A permanent magnet reversible motor moves the group. I f not OK, repair the open circuit to the fuse-
window regulator through an integral gearbox mech block module as required.
anism. A positive and negative battery connection to
the two motor terminals will cause the motor to ONE WINDOW INOPERATIVE
rotate in one direction. Reversing current through The window glass must be free to slide up and down
these same two connections will cause the motor to for the power window motor to function properly. I f the
rotate in the opposite direction. In addition, each glass is not free to move up and down, the motor will
power window motor is equipped with an integral overload and trip the circuit breaker. To determine i f
self-resetting circuit breaker to protect the motor the glass is free, disconnect the regulator plate from the
from overloads. The power window motor and gear glass. Then slide the window up and down by hand.
box assembly cannot be repaired. I f faulty, the entire There is an alternate method to check if the glass is free.
motor assembly must be replaced. Position the glass between the up and down stops. Then,
8S - 2 POWER WINDOW SYSTEMS BR

shake the glass in the door. Check that the glass can be (2) Check the switch continuity in each position, as
moved slightly from side to side, front to rear, and up and shown in the charts (Fig. 1) or (Fig. 2). I f OK, see the
down. Then check that the glass is not bound tight in the Power Window Motor diagnosis in this group. I f not
tracks. If the glass is free, proceed with the diagnosis that OK, replace the faulty switch.
follows. If the glass is not free, refer to Group 23 - Body
Components for window glass service and adjustment pro
cedures.
(1) Check the switch continuity as described in the
Power Window Switch diagnosis in this group. I f OK
and the left front window is inoperative, see the Power
Window Motor diagnosis' in this group. I f OK and the
inoperative window is other than the left front, go to VIEW S H O W N FROM BACK OF SWITCH
Step 2. I f not OK, replace the faulty switch. SWITCH
CONTINUITY BETWEEN
POSITION
(2) With the ignition switch in the On position,
check for battery voltage at the fused ignition switch OFF
PINS 1 & 2, PINS 2 & 3
PINS 3 & 4 , PINS 4 & 6
output circuit cavity of the switch connector. I f OK,
go to Step 3. I f not OK, repair the open circuit to the PINS 1 & 5 , PINS 2 & 3
LEFT
PINS 3 & 4 , PINS 4 & 6
fuseblock module as required. i in
Ur
(3) Refer to the circuit diagrams in 8W-60 - Power Win PINS 1 & 2 , PINS 2 & 4
RIGHT
PINS 3 & 5 , PINS 4 & 6
dows in Group 8W - Wiring Diagrams. Check the continu
PINS 1 & 2, PINS 2 & 3
ity in each circuit between the inoperative power window LEFT
PINS 3 & A, PINS 5 & 6
switch connector cavities and the corresponding left front PUWN '— PINS 1 & 2, PINS 2 & 3
power window switch connector cavities. If OK, see the RIGHT PINS 3 & 6 , PINS 4 & 5
Power Window Motor diagnosis in this group. If not OK,
repair the open circuit(s) as required. J958S-2
Fig. 1 Left Side Switch Continuity
NOTE: All individual power window switches
receive their ground feed through the left front
power window switch and connector.
CIRCUIT BREAKER
For circuit descriptions and diagrams, refer to 8W-60
- Power Windows in Group 8W - Wiring Diagrams.
(1) Locate the correct circuit breaker in the fuseblock
module. Pull out the circuit breaker slightly, but be sure
that the terminals still contact the terminals in the fuse- V I E W S H O W N F R O M BACK OF SWITCH
block module.
(2) Connect the negative lead of a 12-volt DC volt
meter to a good ground. SWITCH CONTINUITY
(3) With the voltmeter positive lead, check both POSITION BETWEEN
terminals of the circuit breaker for battery voltage.
If only one terminal has battery voltage, the circuit PINS 1 & 4
breaker is faulty and must be replaced. I f neither ter OFF PINS 2 & 3
minal has battery voltage, repair the open circuit
from the power distribution center as required.
PINS 1 & 4
UP PINS 3 & 5
POWER WINDOW SWITCH
8W-60 - Power Windows in Group 8W - Wiring Dia PINS 2 & 3
DOWN PINS 1 & 5
grams. Before you proceed with this diagnosis, con
firm proper circuit breaker operation. See the Circuit
Breaker diagnosis in this group.
(1) Remove the switch from the door trim panel as J958S-1
described in this group. Carefully separate the multiple Fig. 2 Right Side Switch Continuity
terminal block on the wiring harness from the switch body.
BR POWER WINDOW SYSTEMS 8S - 3
POWER WINDOW MOTOR

8W-60 - Power Windows in Group 8W - Wiring Dia
grams. Before you proceed with this diagnosis, con
firm proper switch operation. See the Power Window
Switch diagnosis in this group.
(1) Remove the door trim panel as described in
this group.
(2) Disconnect the power window motor connector.
Apply 12 volts across the motor terminals to check
its operation in one direction. Reverse the connec
tions across the motor terminals to check the opera Fig. 4 Switch Bezel Rear Retaining Tab -Typical
tion in the other direction. Remember, i f the window
is i n the full up or full down position, the motor will
not operate in that direction by design. I f OK, repair
the circuits from the motor to the switch as required.
If not OK, replace the faulty motor.
(3) If the motor operates in both directions, check the
window's operation through its complete up and down
travel. If not OK, refer to Group 23 - Body Components
to check the window glass, tracks, and regulator for
sticking, binding, or improper adjustment.
R E M O V A L AND INSTALLATION
POWER WINDOW SWITCH

(1) Disconnect and isolate the battery negative TABS FRONT CLIP' J948S-8
cable. Fig, 5 Door Switch Connectors - Typical

(2) Remove the two screws in the door pull cup
POWER WINDOW MOTOR
and remove the cup (Fig. 3). :
* '(1) Remove the power window switch as described
REMOVE 2 SCREWS in this group.
knob rearward to remove i t from the switch stem
(Fig. 6).
J948S-2
Fig. 3 Door Pull Cup Remove/Install - Typical

(3) Remove power window and lock switches by
reaching through the door pull cup opening and
depressing the switch bezel rear retaining tab (Fig.
4).
(4) Pull the rear of the switch bezel up and away
from the door trim panel.
(5) Unplug the wiring connectors from the
switches (Fig. 5).
Install the switch bezel to the door trim panel by Fig. 6 Power Mirror Switch Knob Remove/Install
inserting the front of the bezel Into trim panel open
ing, then push down on the rear of the bezel until
the retaining tab snaps into place.
8S - 4 POWER WINDOW SYSTEMS — — — mm

switch the (Fig. 7).
Fig. 9 Glass Channel Front Attaching Nut
Fig. 7 Power Mirror Switch Nut

(4) Using a wide. flat-bladed tool such as a trim
NOTE: To aid in the removal of the trim panel, start

(5) Roll the door watershield away from the bot Fig. 10 Glass Channel Rear Attaching Nut
tom of the inner door panel to allow access to the
(7) Slide the glass rearward to disengage the chan
power window regulator screws (Fig. 8).
nel nuts from the slotted holes i n the regulator arm.
(8) Pull the glass to its full up position and tape i t
to the upper door frame.
(9) Unplug the wiring connector from the power
window motor.
(10) Remove the two window track screws and the
two rear regulator screws (Fig. 8).
(11) Loosen the two front regulator screws (Fig. 8).
(12) Remove the power window regulator and
motor unit from the door (Fig. 11).
(13) To install, place the power window regulator
and motor unit inside the door and slide the two
loose front regulator screws into the slotted holes i n
the door.
(14) Install the four remaining regulator and track
screws.
(15) Tighten the regulator screws to 12 N-m (105
Fig. 8 Power Window Regulator Mounting Screws in. lbs.).
(6) Move the door glass to allow access to the glass (16) Move the glass as far rearward into the chan
channel attaching hardware (Fig. 9) and (Fig. 10). nel as possible and push down. Tighten the two win
dow track screws to 12 N-m (105 in. lbs.).
POWER WINDOW SYSTEMS 8S - a
(Fig. 9) and (Fig. 10). Tighten the door glass channel
nuts to 12 N-m (105 in. lbs.).
(18) Connect the wire harness connector to the
power regulator motor.
(19) Using an adhesive/sealant (3M 08041 or
08044 is recommended), install the plastic water-
shield to the door inner panel.
(20) Reverse the remaining removal procedures to
complete the installation.
J948S-7
Fig. 11 Power Window Regulator Remove

(17) Attach the door glass by sliding the two chan
nel nuts into the slotted holes in the regulator arm
BR POWER MIRROR SYSTEMS 8T -1
POWER MIRROR S Y S T E M S
CONTENTS
page page
AUTOMATIC DAY/NIGHT MIRROR 5 OUTSIDE POWER MIRRORS 1
OUTSIDE POWER MIRRORS
INDEX
page page

INTRODUCTION 1 POWER MIRROR SYSTEM • 1
DESCRIPTION AND OPERATION REMO¥AL AND INSTALLATION
POWER MIRROR SWITCH 1 POWER MIRROR SWITCH 2
POWER MIRROR 1 POWER MIRROR ..................... 4
G E N E R A L INFORMATION moved in a joystick fashion to control movement of

the selected mirror up, down, right, or left. The
INTRODUCTION power mirror switch cannot be repaired and, i f faulty,
Power outside rear view mirrors are an available must be replaced as a complete unit.
factory-installed option on this model. Following are
general descriptions of the major components In the
power mirror system. Refer to 8W-62 - Power Mirrors
in Group 8W - Wiring Diagrams for complete circuit
POWER MIRROR SYSTEM
descriptions and diagrams.
8W-62 - Power Mirrors i n Group 8W - Wiring Dia
DESCRIPTION AND OPERATION grams.
(1) Check the fuses i n the Power Distribution Cen
POWER MIRROR ter (PDC) and the fuseblock module. I f OK, go to
The power mirrors are connected to battery feed at Step 2. I f not OK, replace the faulty fuse(s).
all times. Each mirror head contains two electric (2) Check for battery voltage at the fuse in the
motors, two drive mechanisms and the mirror glass. fuseblock module. I f OK, go to Step 3. I f not OK,
One motor and drive controls mirror up-and-down repair the open circuit to the PDC as required.
movement, and the other controls right-and-left (3) Remove the power mirror switch as described
movement. in this group.
The mirror glass is the only serviced replacement (4) Disconnect the wiring harness connector from
part for the power mirror assembly. I f any other com the switch. Check for battery voltage at the fused
ponent of the mirror unit is faulty or damaged, the B(+) circuit cavity of the switch connector. I f OK, go
entire assembly must be replaced. to Step 5. I f not OK, repair the open circuit to the
fuseblock module as required.
POWER MIRROR SWITCH (5) Check for continuity between the ground cir
Both the right and left outside power mirrors are cuit cavity of the switch harness connector and a
controlled by a single multi-function switch. The good ground. There should be continuity. I f OK, go to
switch knob is rotated clockwise (right mirror con Step 6. I f not OK, repair the circuit to ground as
trol) or counterclockwise (left mirror control) to select required.
the mirror to be adjusted. The switch knob is then
8T - 2 POWER MIRROR SYSTEMS BR
(6) Check the switch continuity as shown i n (Fig. (2) Remove the two screws in the door pull cup
1). I f OK, go to Step 7. I f not OK, replace the faulty and remove the cup (Fig. 3).
switch.
REMOVE 2 SCREWS
mm*? §®3@ee@ir COB " L " Positie®

MOVE LEVER
L / B K and P K , YL/PK and IK
YL end P K
YL/PK and P K , D B and B K
DB/WT and BK
YL/PK and P K , Y L and B K

Y L / B K and BK
YL/PK and B K , D B and P K

DB/WT and PK J948S-2
Mirror Selector Knob In " R " Position

- Fig. 3 Door Pull Cup Remove/Install
MOVE L I V E ! CONTINUITY BETWEEN
WT and B K , Y L and P K (3) I f equipped, remove the manual window regu
Y L / B K and PK lator crank handle with a removal tool (Fig. 4).
WT and PK, DB and BK
DB/WT and BK DOOR HANDLE
REMOVAL TOOL
WT and PK, Y L and BK
Y L / B K and BK
WT and BK, DB and P K

DB/WT and P K
J928T-5
Fig. 1 Mirror Switch Continuity

(7) Use two jumper wires, one connected to a
12-volt battery feed, and the other connected to a
good body ground. See the Mirror Test Chart for the
correct jumper wire connections at the power mirror
switch connector (harness side, not switch side) (Fig.
2). I f the mirror(s) don't respond as indicated in the
chart, remove the mirror and check those circuits
between the mirror and the switch for a short or Fig. 4 Window Regulator Crank Handle Remove -
open. I f not OK, repair the circuits as required. I f the Typical
circuits are OK, replace the faulty mirror assembly.
(4) I f equipped, remove the power window and lock
switches by reaching through the door pull cup open
12 Volts Ground light ing and depressing the switch bezel rear retaining
YL/BK WT UP
tab (Fig. 5).
YL YL/PK UP
WT YL/BK D O W N
YL/PK YL D O W N
WT DB RIGHT
YL/PK DB/WT RIGHT

DB WT LEFT
DB/WT YL/PK LEFT
J928T-4
Fig. 2 Mirror Test Chart

Fig. 5 Switch Bezel Rear Retaining Tab
POWER MIRROR SWITCH (5) Pull the rear of the switch bezel up and away
(1) Disconnect and isolate the battery negative from the door trim panel.
cable.
BR POWER MIRROR SYSTEMS 8T - 3

(6) Unplug the wiring connectors from the SWITCH RETAINING
switches (Fig. 6). NUT
DOOR TRIM-
PANEL
CONNECTOR
LOCKING SWITCH PANEL
TABS FRONT CLIP J948S-8
Fig. 6 Door Switch Connectors

(7) Pull the power mirror switch control knob rear POWER MIRROR
ward to remove it from the switch stem (Fig. 7). SWITCH J948T-5
DOOR TRIM
PANEL Fig. 8 Power Mirror Switch Nut
(10) Unplug the power mirror switch wiring con
SWITCH CONTROL nector (Fig. 9).
KNOB
POWER MIRROR
- SWITCH — ? J948T-6
Fig. 7 Power Mirror Switch Knob Remove/install

the switch (Fig. 8). J948T-4
stick, pry the trim panel away from the door around Fig. 9 Power Mirror Switch Connector
(11) Remove the power mirror switch from the
NOTE: To aid in the removal of the trim panel, start door trim panel.
at the bottom of the panel. (12) Reverse the removal procedures to install.
8T - 4 POWER MIRROR SYSTEMS BR
POWER MIRROR
(1) Remove the door trim panel as described in
Power Mirror Switch in this group.
(2) Unplug the power mirror motor wiring connec
tor (Fig. 10).
(3) Remove the three nuts holding the mirror to
the door.
(4) Pull the mirror, wiring, and grommet from the
outside of the door.
Fig. 10 Power Mirror Remove/instail

BR POWER MIRROR SYSTEMS 8T - 5
AUTOMATIC DAY/NIGHT MIRROR
INDEX
page page

INTRODUCTION 5 AUTOMATIC DAY/NIGHT MIRROR . 5
AUTOMATIC DAY/NIGHT MIRROR 5 AUTOMATIC DAY/NIGHT MIRROR 6
G E N E R A L INFORMATION DIAGNOSIS AND TESTING
INTRODUCTION AUTOMATIC DAY/NIGHT MIRROR

An automatic dimming inside day/night rear view For circuit descriptions and diagrams, refer to
mirror is an available factory-installed option on this 8W-44 - Interior Lighting in Group 8W - Wiring Dia
model. Following is a general description of this grams.
optional equipment. Refer to 8W-44 - Interior Light (1) Check the fuse in the fuseblock module. I f OK,
ing in Group 8W - Wiring Diagrams for complete cir go to Step 2. I f not OK, replace the faulty fuse.
cuit descriptions and diagrams. (2) Turn the ignition switch to the On position.
Check for battery voltage at the fuse i n the fuseblock
module. I f OK, go to Step 3. I f not OK, repair the
DESCRIPTION AND OPERATION open circuit to the ignition switch as required.
(3) Unplug the wiring connector from the mirror
AUTOMATIC DAY/NIGHT MiFtlOFt (Fig. 1). Check for battery voltage at the fused igni
The automatic day/night mirror is able to automat tion switch output circuit cavity of the mirror connec
ically change its reflectance. A thin layer of electro- tor. I f OK, go to Step 4. I f not OK, repair the open
chromic material between two pieces of conductive circuit to the fuseblock module as required.
glass make up the face of the mirror. Two photocell
sensors are used to monitor light levels and adjust
the mirror's reflectance to reduce the glare of head
lamps approaching the vehicle from the rear.
The ambient photocell sensor faces forward, to
detect the outside light levels. The headlamp sensor
faces rearward, to detects the light level received at
the rear window side of the mirror. When the differ
ence between the two light levels becomes too great
(the light level received at the rear of the mirror is
much higher than at the front of the mirror), the
mirror begins to darken.
The mirror switch allows the driver a manual con
trol of whether the automatic dimming feature is
operational. When On is selected, the mirror switch
is lighted by an integral Light-Emitting Diode (LED). FORWARD FACING SENSOR J948T-9
The automatic dimming feature will only operate

when the ignition switch is in the On position. The Fig, 1 Automatic Day/Night Mirror
mirror also senses the back-up lamp circuit, and dis (4) Turn the ignition switch to the Off position.
ables the self-dimming feature whenever the trans Check for continuity between the ground circuit cav
mission (manual or automatic) gear selector is in the ity of the mirror connector and a good ground. There
Reverse position. should be continuity. I f OK, go to Step 5. I f not OK,
The automatic day/night mirror cannot be repair the circuit to ground as required.
repaired. I f faulty, the entire assembly must be (5) Turn the ignition switch to the On position. Set
replaced. the parking brake. Place the transmission gear selec
tor lever in the Reverse position. Check for battery
voltage at the back-up lamp switch output circuit
8T - i POWER MIRROR SYSTEMS

cavity of the mirror connector. I f OK, plug the mirror (2) I f so equipped, remove the wire cover by grasping
connector in and go to Step 6. I f not OK, repair the the lower portion of the wire cover and sliding it into
open circuit as required. the upper portion and off of the mirror base (Fig. 2).
(6) Place the transmission gear selector lever in
the Neutral position. Place the mirror switch in the
On (switch LED lighted) position. Cover the forward
facing ambient photocell sensor to keep out any
ambient light.
NOTE: The ambient photocell sensor must be cov

ered completely, so that no light reaches the sen
sor. Use a finger pressed tightly against the sensor,
or cover the sensor completely with electrical tape.
(7) Shine a light into the rear facing headlamp
photocell sensor. The mirror should darken. I f OK, go
to Step 8. I f not OK, replace the faulty mirror unit.
(8) With the mirror darkened, place the transmis
sion gear selector lever in the Reverse position. The ON/OFF • ELECTRICAL
SWITCH CONNECTOR
mirror should return to its normal condition. I f not
OK, replace the faulty mirror unit. Fig, 2 Automatic Day/Night Mirror Remove/Install
(3) Unplug the wiring connector from the mirror.
REMOVAL AND INSTALLATION (4) Remove the setscrew holding the mirror to the
windshield support button.
AUTOMATIC DAY/NIGHT MIRROR (5) Push the mirror up far enough to clear the sup
(1) Disconnect and isolate the battery negative port button and remove the mirror.
cable. (6) Reverse the removal procedures to install.
BR CHIME/BUZZER WARNING SYSTEMS 8U - 1
CHIME/BUZZER W A R N I N G S Y S T E M S
CONTENTS
page page
GENERAL INFORMATION DRIVER'S DOOR JAMB SWITCH 2

INTRODUCTION 1 DRIVER'S SEAT BELT SWITCH 3
DESCRIPTION AND OPERATION HEADLAMP SWITCH 3
BUZZER MODULE 1 IGNITION KEY-IN SWITCH 2
DRIVER'S DOOR JAMB SWITCH 1 REMOVAL AND INSTALLATION
DRIVER'S SEAT BELT SWITCH 2 BUZZER MODULE 3
HEADLAMP SWITCH 1 CHIME/BUZZER WARNING SYSTEM
IGNITION KEY-IN SWITCH 1 SWITCHES 4
BUZZER MODULE 2
G E N E R A L INFORMATION DRIVER'S POOR JAMB SWITCH

The driver's door jamb switch is mounted to the
INTRODUCTION driver's door hinge pillar. The switch closes a path to
This group covers the buzzer warning system, ground for the buzzer module through the key-in
which is standard factory-installed equipment on this switch or the headlamp switch when the driver's door
model. The system provides an audible warning to Is opened, and opens when the driver's door is closed.
the driver when It monitors the following conditions: This switch cannot be repaired and, i f faulty, must be
• The key is in the ignition switch with the driv replaced. Refer to. Group 8L - Lamps for the service
er's door open. procedures.
• The head or park lamps are on with the driver's
door open. IGNITION KEY-IN SWITCH
• The driver's seat belt is not buckled with the The ignition key-in switch is integral to the igni
ignition switch in the On position. tion switch, which Is mounted on the right side of the
Following are general descriptions of the major steering column. I t closes a path to ground for the
components in the buzzer warning system. Refer to buzzer module when the Ignition key is inserted i n
8W-44 - Interior Lighting in Group 8W - Wiring Dia the ignition lock cylinder and the driver's door jamb
grams for complete circuit descriptions and diagrams. switch Is closed (door open). The switch opens when
the key is removed from the ignition lock cylinder.
This switch cannot be repaired and, i f faulty, the
DESCRIPTION AND OPERATION entire ignition switch must be replaced. Refer to
Group 8D - Ignition. Systems for the service proce
BUZZER MODULE dures.
The buzzer module receives battery voltage at all
times from a fuse i n * the fuseblock module. I t also HEADLAMP SWITCH
receives a second battery feed through a fuse in the The headlamp switch is located in the instrument
fuseblock module when the ignition switch is in the panel. I t closes a path to ground for the buzzer mod
On or Start position. ule when the park or head lamps are on and the
Other inputs to the module include the driver's driver's door jamb switch is closed (door open). The
door jamb switch, the driver's seat belt switch, the switch opens the ground path when the park and
ignition key-in switch, and the headlamp switch. The head lamps are turned off. The headlamp switch can
only output of the module is a timed four to eight not be repaired and, if faulty, must be replaced. Refer
second feed to the seat belt reminder lamp on the to Group 8E - Instrument Panel Systems for the ser
instrument panel. The timer function begins after vice procedures.
the ignition switch is turned to the On position.
The buzzer module cannot be repaired. I f faulty, i t
must be replaced.
8U - 2 CHIME/BUZZER WARNING SYSTEMS BR
DRIVER'S SEAT BELT SWITCH (1) Open the driver's door and note whether the
The driver's seat belt switch is integral to the driv interior lamps light. They should light. I f OK, see the
er's seat belt buckle-half assembly. The switch is nor diagnosis for the Ignition Key-In Switch or the Head
mally closed, providing a ground path to the buzzer lamp Switch in this group. I f not OK, go to Step 2.
module. When the tip-half of the seat belt is inserted (2) Check for continuity between the ground cir
into the seat belt buckle, the switch opens the buzzer cuit cavity of the driver's door jamb switch connector
ground path. The seat belt switch cannot be repaired. and a good ground. There should be continuity. I f
If faulty, the entire driver's seat belt buckle-half unit OK, go to Step 3. I f not OK, repair the circuit to
must be replaced. Refer to Group 23 - Body Compo ground as required.
nents for the service procedures. (3) Check for continuity between the ground cir
cuit terminal and each of the two courtesy lamps
driver terminals of the door jamb switch. There
DIAGNOSIS AND TESTING should be continuity with the switch plunger
released, and no continuity with the switch plunger
BUZZER MODULE depressed. I f not OK, replace the faulty switch.
8W-44 - Interior Lighting in Group 8W - Wiring Dia IGNITION KEY-IN SWITCH
grams. For circuit descriptions and diagrams, refer to
(1) Check the fuse(s) in the fuseblock module. I f 8W-44 - Interior Lighting i n Group 8W - Wiring Dia
OK, go to Step 2. I f not OK, replace the faulty grams.
fuse(s).
(2) Check for battery voltage at the hot at all WARNING: ON VEHICLES EQUIPPED WITH AN AIR-
times fuse in the fuseblock module. I f OK, go to Step BAG, REFER TO GROUP 8M • PASSIVE RESTRAINT
3. I f not OK, repair the open circuit from the power SYSTEMS BEFORE ATTEMPTING STEERING
distribution center as required. WHEEL OR STEERING COLUMN COMPONENT
(3) Turn the ignition switch to the On position. DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
Check for battery voltage at the hot in run and start PROPER PRECAUTIONS COULD RESULT IN ACCI
fuse in the fuseblock module. I f OK, go to Step 4. I f DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
not OK, repair the open circuit from the ignition PERSONAL INJURY.
switch as required.
(4) Turn the ignition switch to the Off position. (1) Remove the steering column shrouds. Refer to
Replace the buzzer module with a known good unit Group 8D - Ignition Systems for the procedures.
and test its operation. I f OK, discard the faulty Unplug the ignition key-in switch connector from the
buzzer module. I f not OK, remove the buzzer module ignition switch (Fig. 1).
and go to Step 5. KEY-IN SWITCH & MULTI-FUNCTION
(5) Check for battery voltage at the fused B(+) cir
cuit cavity of the buzzer module connector. I f OK, go
to Step 6. I f not OK, repair the open circuit to the
fuseblock module as required.
Check for battery voltage at the fused ignition switch
output circuit cavity of the buzzer module connector.
If OK, go to Step 7. I f not OK, repair the open circuit
to the fuseblock module as required.
Check for continuity between the ground circuit cav
ity of the buzzer module connector and a good
ground. There should be continuity. I f OK, go to the
diagnosis for the switch that is related to the buzzer
SWITCH CONTROL J918J-2
malfunction. I f not OK, repair the circuit to ground
as required.
Fig. 1 Key-In Switch Connector
DRIVERS DOOR JAMB SWITCH (2) Open the driver's door. Check for continuity
For circuit descriptions and diagrams, refer to between the left front door jamb switch sense circuit
8W-44 - Interior Lighting in Group 8W - Wiring Dia cavity of the key-in switch connector and a good
grams. ground. There should be continuity. I f OK, go to Step
CHIME/BUZZER WARNING SYSTEMS 8U - 3
mm
D I A G N O S I S AMD TESTING ( C o n t i n u e d )
3. I f not OK, repair the open circuit to the driver's ties of the seat belt half *of the connector. There
door jamb switch as required. should be continuity with the seat belt unbuckled,
(3) Insert the ignition key in the ignition lock cyl and no continuity with the seat belt buckled. I f OK,
inder. Check for continuity between the key-in switch go to Step 2. I f not OK, replace the faulty seat belt
sense circuit and the left front door jamb switch buckle-half assembly.
sense circuit terminals of the key-in switch. There (2) Check for continuity between the ground cir
should be continuity until the key is removed. I f OK, cuit cavity in the harness half of the seat belt switch
go to Step 4. I f not OK, replace the faulty ignition connector and a good ground. There should be conti
switch. nuity. I f OK, go to Step 3. I f not OK, repair the cir
(4) Check for continuity between the key-in switch cuit to ground as required.
sense circuit cavities of the key-in switch connector (3) Check for continuity between the seat belt
and the buzzer module connector. There should be switch sense circuit cavities in the harness half of
continuity. I f not OK, repair the open circuit to the the seat belt switch connector and the buzzer module
buzzer module as required. connector. There should be continuity. I f not OK,
HEADLAMP SWITCH
8W-44 - Interior Lighting in Group 8W - Wiring Dia R E M O V A L AND INSTALLATION
grams.
(1) Remove the headlamp switch from the instru BUZZER MODULE
ment panel. Refer to Group 8E - Instrument Panel (1) Disconnect and isolate the battery negative
Systems for the procedures. Unplug the headlamp cable.
switch connector. Open the driver's door. Check for (2) Remove the five screws securing the knee
continuity between the left front door jamb switch blocker to the lower instrument panel (Fig. 2).
sense circuit cavity of the headlamp switch connector
and a good ground. There should be continuity until
the driver's door is closed. I f OK, go to Step 2. I f not
OK, repair the circuit to the driver's door jamb
switch as required.
(2) Check for continuity between the key-in igni
tion switch sense circuit cavities of the headlamp
switch connector and the buzzer module connector.
There should be continuity. I f OK, go to Step 3. I f not
OK, repair the open circuit to the buzzer module as
required.
(3) Check for continuity between the left front door
jamb switch sense circuit and the key-in ignition
switch sense circuit terminals of the headlamp
switch. There should be no continuity with the
switch i n the Off position, and there should be conti
nuity with the switch in the park or head lamps On Fig. 2 Knee Blocker Remove/Install
position. I f not OK, replace the faulty headlamp (3) The buzzer module connector is on a bracket
switch. attached to the lower instrument panel reinforcement
just inboard of the steering column. Release the con
DRIVER'S SEAT BELT SWITCH
nector latch from the buzzer module and unplug the
module from the connector.
8W-44 - Interior Lighting in Group 8W - Wiring Dia
(4) To install, align the buzzer module terminals
grams.
and latch tab with the connector cavities and latch,
(1) Unplug the seat belt switch connector on the
then push the module firmly into place.
floor under the driver's seat near the seat belt buck
(5) Install the knee blocker.
le-half anchor. Check for continuity between the seat
(6) Connect the battery negative cable.
belt switch sense circuit and the ground circuit cavi
(7) Test the buzzer module operation.
8U - 4 CHIME/BUZZER WARNING SYSTEMS BR
CHIME/BUZZER WARNING SYSTEM SWITCHES • Headlamp switch - refer to Group 8E - Instru
Service procedures for the various switches used in ment Panel Systems
the chime/buzzer warning system can be found in the • Driver's seat belt switch - refer to Group 23 -
appropriate group as follows: Body Components.
• Driver's door jamb switch - refer to Group 8L -
Lamps
• Ignition key-in switch - refer to Group 8D - Igni
tion Systems
OVERHEAD CONSOLE SYSTEMS 8V - 1
O V E R H E A D C O N S O L E SYSTEMS
CONTENTS
page page
GENERAL INFORMATION COMPASS DEMAGNETIZING 5

INTRODUCTION 1 COMPASS VARIATION ADJUSTMENT 4
COMPASS 1 COMPASS/THERMOMETER/DISPLAY
READING/COURTESY LAMPS 2 MODULE 6
THERMOMETER 1 OVERHEAD CONSOLE 5
DIAGNOSIS AND TESTING READING/COURTESY LAMP BULBS 7
COMPASS/DISPLAY MODULE 2 TEMPERATURE SENSOR 6
THERMOMETER 2
SERVICE PROCEDURES
COMPASS CALIBRATION 4
G E N E R A L INFORMATION assembly to the roof header can also affect compass

operation. I f the vehicle roof should become magne
INTRODUCTION tized, the demagnetizing and calibration procedures
An overhead console featuring an electronic com found in this group may be required to restore proper
pass and thermometer is an available factory-in compass operation.
stalled option on this model. Following are general The compass, thermometer, and display module
descriptions of the major components used in the cannot be repaired, and are only available for service
overhead console. Refer to 8W-49 Overhead Console as a unit. I f faulty, the complete assembly must be
in Group 8W - Wiring Diagrams for complete circuit replaced.
descriptions and diagrams.
THERMOMETER
The thermometer displays the outside ambient
DESCRIPTION AND OPERATION temperature. The temperature display can be
changed from Fahrenheit to, Celsius using the
COMPASS US/Metric button, located to the right of the display
The compass will display the direction i n which the module. The displayed temperature is not an instant
vehicle is pointed using the eight major compass reading of conditions, but an average temperature. I t
headings (Examples: north is N , northeast is NE). I t may take the thermometer display several minutes
does not display the headings in actual degrees. The to respond to a major temperature change, such as
display is turned on or off using the Comp/Temp but driving out of a heated garage into winter tempera
ton, located to the left of the display module. tures.
The . self-calibrating compass unit requires no When the ignition switch is turned to the Off posi
adjusting i n normal use. The only calibration that tion, the last displayed temperature reading stays i n
may prove necessary is to drive the vehicle in three the thermometer unit memory. When the ignition
complete circles, on level ground, in not less than 48 switch is turned to the On position again, the ther
seconds. This will reorient the compass unit to its mometer will display the memory temperature for
vehicle. one minute; then update the display to the current
The compass unit also will compensate for magne average temperature reading within five minutes.
tism the body of the vehicle may acquire during nor The thermometer function is supported by an
mal use. However, avoid placing anything magnetic ambient temperature sensor. The sensor is mounted
directly on the roof of the vehicle. Magnetic mounts outside the passenger compartment near the front
for an antenna, a repair order hat, or a funeral pro and center of the vehicle. The ambient temperature
cession flag can exceed the compensating ability of sensor is available as a separate service item.
the compass unit i f placed on the roof panel. Mag The compass, thermometer, and display module
netic bit drivers used on the fasteners that hold the cannot be repaired, and are only available for service
8V - 2 OVERHEAD CONSOLE SYSTEMS BR
as a unit. I f the module is faulty, the complete SELF-DIAGNOSTICS
assembly must be replaced. A self-diagnostic test is used to determine that the
compass, and all of the display module segments are
READING/COURTESY LAMPS operating properly electrically. Initiate the self-diag
All reading and courtesy lamps located in the over nostic test as follows:
head console are activated by the door jamb switches. (1) With the ignition switch in the Off position,
When the doors are closed, the lamps can be individ simultaneously press and hold the Comp/Temp but
ually activated by depressing the corresponding lens. ton and the US/Metric button.
When a door is open, depressing the lamp lens (2) Turn the ignition switch to the On position.
switches will not turn the lamps off. Refer to Group (3) Continue to hold both buttons, until the display
8L - Lamps, for diagnosis and service of the reading module performs a walking segment test. In this test,
and courtesy lamps. all of the compass points are displayed, along with
various number combinations. These combinations
verify that all of the display module segments are
DIAGNOSIS AND TESTING functional. I f any segment should fail to light during
the test, the unit is faulty and must be replaced. To
COMPASS/DISPLAY MODULE repeat the test, momentarily depress and release the
I f the problem with the compass/display module is Comp/Temp button one time.
an inaccurate or scrambled display, use the Self-Di (4) Momentarily depress and release the US/Met
agnostics procedures. I f the problem is a no-display ric button one time. All of the display segments will
condition, use the following procedures. For circuit light simultaneously for about two seconds. I f any
descriptions and diagrams, refer to 8W-49 - Overhead segment should fail to light during the test, the unit
Console in Group 8W - Wiring Diagrams. is faulty and must be replaced. To repeat the test,
(1) Check the fuses in the fuseblock module. I f OK, momentarily depress and release the Comp/Temp
go to Step 2. I f not OK, replace the faulty fuse(s). button one time.
(2) Remove the overhead console as described in (5) Momentarily depress and release the US/Met
this group. Check for continuity between each of the ric button one time, or turn the ignition switch to the
two ground circuit cavities of the overhead console Off position to exit the self-diagnostic mode and
connector and a good ground. There should be conti return the compass and display module to normal
nuity. I f OK, go to Step 3. I f not OK, repair the cir operation.
cuits to ground as required.
(3) Check for battery voltage at each of the two NOTE: If the compass functions, but accuracy is
fused B(+) circuit cavities of the overhead console suspect, it may be necessary to perform a variation
connector. I f OK, go to Step 4. I f not OK, repair the adjustment. This procedure allows the compass
open circuit(s) to the fuseblock module as required. unit to accommodate variations in the earth's mag
(4) Turn the ignition switch to the On position. netic field strength, based on geographic location.
Check for battery voltage at the fused ignition switch See the Compass Variation Adjustment procedures,
output cavity of the overhead console connector. I f in this group.
OK, go to Step 5. I f not OK, repair the open circuit to
the fuseblock module as required.
(5) Check for battery voltage at the park lamp NOTE: If the compass reading has blanked out, and
switch output circuit cavity of the overhead console only "CAL" appears in the display module, demag
connector. There should be zero volts with the head netizing may be necessary to remove excessive
lamp switch in the Off position, and battery voltage residual magnetic fields from the vehicle. See the
with the park or head lamps turned on. I f OK, go to Compass Demagnetizing procedure, in this group.
Step 6. I f not OK, repair the open circuit to the head
lamp switch as required.
(6) Check for voltage at the fused panel lamps THERMOMETER
dimmer switch signal cavity of the overhead console The thermometer function is supported by a tem
connector. There should be zero volts with the head perature sensor, a wiring circuit, and a portion of the
lamp switch i n the Off position. When the park or overhead console compass/display module display.
head lamps are turned on, the voltage should vary as The sensor is mounted outside the passenger com
the dimmer switch is rotated. I f OK, replace the partment near the front and center of the vehicle.
faulty compass/display module. I f not OK, repair the If any portion of the temperature sensor circuit
open circuit to the fuseblock module as required. fails, the thermometer display will self-diagnose the
circuit. An "SC" (short circuit) will appear on the dis
play module i n place of the temperature when the
BR . OVERHEAD CONSOLE SYSTEMS 8V - 3
OVERHEAD CONSOLE 1. Display has been switched off. 1. Depress COMP/TEMP button to switch
DISPLAY COMPLETELY unit to compass or thermometer display
DARK option.
2. Faulty fuse or headlamp delay 2. Refer to Group 8L — Lamps, for
module. diagnosis and service of this circuit.
3. Faulty wiring. 3. Refer to Group 8W — Wiring Diagrams
for circuit diagrams. Check and repair
wiring, if required.
4. Faulty compass/thermometer 4. Replace compass/thermometer display
display module. module, if required.
OVERHEAD CONSOLE 1. Faulty compass/thermometer 1. See Self-Diagnostic Test, in this group.
DISPLAY SEGMENTS display module. Replace compass/thermometer display
MISSING module, if required.
ERRATIC COMPASS 1. Magnet or strong magnetic field 1. Remove magnet and perform
OPERATION near compass module. Demagnetizing Procedure, in this group.
2. Variance setting incorrect. 2. See Variation Adjustment Procedure in
3. Calibration incorrect. this group.
4. Faulty compass/thermometer 3. See Calibration Procedure, in this group.
display module. 4. Replace compass/thermometer display
module, if required.
ERRATIC THERMOMETER 1. Faulty sensor wiring. 1. See Sensor Circuit Test, in this group.
OPERATION Repair wiring, if required.
2. Faulty sensor. 2. See Sensor Test, in this group. Replace
sensor, if required.
3. Faulty compass/thermometer 3. Replace compass/thermometer display
display module. module, if required.
J958C-1
neter Diagnosis
sensor is exposed to temperatures above 55°C between these two values. I f OK, go to the Sensor
(131°F), or i f the sensor circuit is shorted. An "OC" Circuit Test. I f not OK, replace the faulty sensor.
(open circuit) will appear in place of the temperature
when the sensor is exposed too temperatures below s e n s o n CIRCUIT TEST
-40°C (-40°F), or i f the sensor circuit is open. (1) Turn the ignition switch to the Off position.
The temperature sensor circuit can also be diag Unplug the temperature sensor connector.
nosed using the following Sensor Test, and Sensor (2) Connect a jumper wire between the two termi
Circuit Test. I f the temperature sensor and circuit nals i n the body half of the sensor connector.
are confirmed to be OK, but the temperature display (3) Remove the overhead console . as described i n
is inoperative • or incorrect, see the Compass/Display this group. Disconnect the overhead console wiring
Module diagnosis i n this group. For circuit descrip connector.
tions and diagrams, refer to 8W-49 - Overhead Con (4) Check for continuity between the sensor
sole i n Group 8W - Wiring Diagrams. ground circuit and the ambient temperature sensor
signal circuit cavities of the overhead console connec
SENSOR TEST - . tor. There should be continuity. I f OK, go to Step 5. I f
(1) Turn the ignition switch to the Off position. not OK, repair the open circuit as required.
Unplug the temperature sensor connector. (5) Remove the jumper wire from the temperature
(2) Measure the resistance of the temperature sen sensor connector. Check for continuity between the
sor. At -40°C (-40°F), the sensor resistance is 336K sensor ground circuit cavity of the overhead console
ohms. At 55°C (140°F), the sensor resistance is connector and a good ground. There should be no
2.488K ohms. The sensor resistance should read
8V - 4 OVERHEAD CONSOLE SYSTEMS mm

continuity. I f OK, go to Step 6. I f not OK, repair the appears in the display module. This takes about five
short circuit as required. seconds.
(6) Check for continuity between the ambient tem (4) Release both of the buttons. The zone number
perature sensor signal circuit cavity of the overhead will appear in the display module.
console connector and a good ground. There should (5) Press and release the US/Metric button to step
be no continuity. I f OK, see the Compass/Display through the zone numbers, until the zone number for
Module diagnosis in this group. I f not OK, repair the your area appears in the display.
short circuit as required. (6) Press the Comp/Temp button to enter this zone
number into the compass unit memory.
(7) Confirm that the correct directions are now
SERVICE PROCEDURES indicated.
COMPASS VARIATION ADJUSTMENT COMPASS CALIBRATION
Variance is the difference between magnetic north
and geographic north. I n some areas, the difference CAUTION: Do not place any external magnets, such
between magnetic and geographic north is great as magnetic roof mount antennas, in the vicinity of
enough to cause the compass to give false readings. I f the compass. Do not use magnetic tools when ser
this problem occurs, the compass variance must be vicing the overhead console.
set.
To set the compass variance: The electronic compass unit features a self-cali-
(1) Using the Variance Settings map, find your brating design, which simplifies the calibration pro
geographic location and note the zone number (Fig. cedure. This feature automatically updates the
1). . compass calibration while the vehicle is being driven.
This allows the compass unit to compensate for small
changes in the residual magnetism that the vehicle
may acquire during normal use. Do not attempt to
calibrate the compass near large metal objects such
as other vehicles, large buildings, or bridges.
NOTE: Whenever the compass is calibrated manu

ally, the variation number must also be reset. See
the Compass Variation Adjustment procedure, in
this group.
Calibrate the compass manually as follows:

(1) Start the engine.
(2) Depress both the US/Metric and Comp/Temp
buttons. Hold down both buttons until "CAL" appears
in the display module. This takes about ten seconds,
and appears about five seconds after "VAR" is dis
played.
(3) Release both buttons.
(4) Drive the vehicle on a level surface, away from
large metal objects, through three or more complete
circles in not less than 48 seconds. The "CAL" mes
sage will disappear from the display to indicate that
the compass is now calibrated.
NOTE: If the "CAL" message remains in the dis

play, either there is excessive magnetism near the
compass, or the unit is faulty. Repeat the demagne
tizing and calibration procedures at least one more
Fig. 1 Variance Settings time.
(3) Depress both the US/Metric, and the Comp/
Temp buttons. Hold the buttons down until "VAR"
BR OVERHEAD CONSOLE SYSTEMS 8V - 5
NOTE: If the wrong direction is still indicated in the (4) Slowly approach the center line of the roof
compass display, the area selected for calibration panel at the windshield header, with the degaussing
may be too close to a strong magnetic field. Repeat tool plugged in.
the calibration procedure in another location. (5) Contact the roof panel with the tip of the tool.
Be sure the template is i n place to avoid scratching
the roof panel. Using a slow, back-and-forth sweeping
COMPASS DEMAGNETIZING motion, and allowing 1/2-inch between passes, move
A degaussing tool (Special Tool 6029) is used to the tool at least four inches to each side of the roof
demagnetize, • or degauss, the roof panel. Equivalent center line, and eleven inches back from the wind
units must be fated as continuous duty for 110/115 shield header.
volts and 60Hz. They must also have a field strength (6) With the degaussing tool still energized, slowly
of over 350 gauss at ~ 1/4-inch beyond the tip of the back it away from the roof panel. When the tip of the
probe. tool is at least two feet from the roof panel, unplug
To demagnetize the roof panel, proceed as follows: the tool.
(1) Be certain the ignition switch is i n the Off posi (7) Calibrate the compass and adjust the compass
tion, before you begin the demagnetizing procedure. variance as described in this group.
(2) Place an 8-1/2 X 11-inch piece of paper, ori
ented on the vehicle lengthwise from front to rear, on
the center line of the roof at the windshield header REMOVAL AND INSTALLATION
(Fig. 2). The purpose of the paper is to protect the
roof panel from- scratches, and to define the area to OVERHEAD CONSOLE
be demagnetized. (1) Disconnect and isolate the battery negative
cable.
PULL TIP OF DEGAUSSING TOOL AWAY (2) Remove the two console mounting screws (Fig.
AT LEAST TWO FEET AND 3)..--
C DISCONNECT
c
C
3
C 1/2"
c
3
c 'WINDSHIELD EDGE"
START
J908E-27
Fig. 2 Roof Demagnetizing Pattern J948G5

(3) Plug in the degaussing tool, while keeping the
tool at least two feet away from the compass unit. Fig. 3 Console Mounting Screws
8V - 6 OVERHEAD CONSOLE SYSTEMS BR
(3) Pull the front of the console down slightly, then . (3) Unplug the lighting harness connector from the
move i t rearward until the mounting clips detach compass/thermometer/display module (Fig. 6).
from the roof panel (Fig. 4).
Fig. 6 Lighting Harness Connector

(4) Remove the module from the overhead console
housing.
TEMPERATURE SENSOR
Fig. 4 Overhead Console Remove/Install cable.
(4) Disconnect the wire harness connector from the (2) Locate the temperature sensor, on the radiator
compass/thermometer/display module. support on the driver's side just behind the grille
(5) Reverse the removal procedures to install. (Fig. 7).
COMPASS/THERMQSVIETER/DISPLAY MODULE
(1) Remove the overhead console as described in
this group.
(2) Remove the three screws securing the compass/
thermometer/display module to the overhead console
housing (Fig. 5).
Fig. 7 Temperature Sensor

(3) Unplug the temperature sensor wiring connec
tor.
(4) Remove the temperature sensor mounting bolt
and remove the sensor.
J948C3 (5) Reverse the removal procedures to install.
Fig. 5 Compass/Thermometer/Display Module
Remove/Install
BR OVERHEAD CONSOLE SYSTEMS 8V - 7

READING/COURTESY LAMP BULBS (3) Install a new bulb by pushing i t firmly into the
socket.
(1) Insert a long flat-bladed tool at the notch on,
the curved edge of the lens. Carefully pry the lens (4) Pivot the lens up into position and press
upwards until i t snaps into place.
downward from the housing and pivot the lens down.
(5) Test the lamp by depressing the lens to check
It may be necessary to move the tool along the edge
for proper switching and lighting.
of the lens to free the lens from the console housing.
(2) Remove the bulb by pulling i t straight down.
BR WIRING DIAGRAMS BW-1
WIRING D I A G R A M S
CONTENTS
page page
8W-01 GENERAL INFORMATION 8W-01-1 8W-44 INTERIOR LIGHTING 8W-44-1

8W-02 COMPONENT INDEX 8W-02-1 8W-46 MESSAGE CENTER 8W-46-1
8W-10 FUSE/FUSE BLOCK 8W-10-1 8W-47 AUDIO SYSTEM 8W-47-1
8W-11 POWER DISTRIBUTION 8W-11-1 8W-49 OVERHEAD CONSOLE 8W-49-1
8W-12 JOINT CONNECTORS 8W-12-1 8W-50 FRONT LIGHTING 8W-50-1
8W-15 GROUND DISTRIBUTION 8W-15-1 8W-51 REAR LIGHTING 8W-51-1
8W-20 CHARGING SYSTEM 8W-20-1 8W-52 TURN SIGNALS 8W-52-1
8W-21 STARTING SYSTEM 8W-21-1 8W-53 WIPERS 8W-53-1
8W-30 FUEL/IGNITION SYSTEMS 8W-30-1 8W-54 TRAILER TOW 8W-54-1
8W-31 TRANSMISSION CONTROLS . . . . 8W-31-1 8W-60 POWER WINDOWS 8W-60-1
8W-33 VEHICLE SPEED CONTROL 8W-33-1 8W-61 POWER DOOR LOCKS 8W-61-1
8W-34 REAR WHEEL ANTI-LOCK 8W-62 POWER MIRRORS 8W-62-1
BRAKES 8W-34-1 8W-63 POWER SEAT 8W-63-1
8W-35 ALL-WHEEL ANTI-LOCK BRAKES . 8W-35-1 8W-70 SPLICE INFORMATION 8W-70-1
8W-40 INSTRUMENT CLUSTER 8W-40-1 8W-80 CONNECTOR PIN-OUTS 8W-80-1
8W-41 HORN/CIGAR LIGHTER/POWER 8W-90 CONNECTOR/GROUND
OUTLET 8W-41-1 LOCATIONS 8W-90-1
8W-42 AIR CONDITIONING/HEATER . . . . 8W-42-1 8W-95 SPLICE LOCATIONS . . . . . . . . . . . 3W-95-1
8W-43 AIRBAG SYSTEM 8W-43-1
BR 8W - 01 GENERAL INFORMATION 8W - 01 -1
8W-01 GENERAL INFORMATION
INDEX
page page
DESCRIPTION AND OPERATION TROUBLESHOOTING TESTS 6

CIRCUIT IDENTIFICATION 2 TROUBLESHOOTING TOOLS 5
CONNECTOR/GROUND LOCATIONS 1 TROUBLESHOOTING WIRING PROBLEMS 6
CONNECTORS 2 SERVICE PROCEDURES
ELECTROSTATIC DISCHARGE (ESD) CONNECTOR AND TERMINAL REPLACEMENT . . 9
SENSITIVE DEVICES 5 CONNECTOR REPLACEMENT 8
HOW TO USE THIS GROUP 1 DIODE REPLACEMENT 10
NOTES, CAUTIONS, and WARNINGS 1 TERMINAL REPLACEMENT 10
SECTION IDENTIFICATION 1 TERMINAL/CONNECTOR REPAIR-MOLEX
SPLICE LOCATIONS 1 CONNECTORS 7
SYMBOLS 3 TERMINAL/CONNECTOR REPAIR—THOMAS
TAKE OUTS 3 AND BETTS CONNECTORS 8
WIRE CODE IDENTIFICATION 2 WIRING REPAIR 7
DIAGNOSIS AND TESTING S P E C I A L TOOLS
INTERMITTENT AND POOR CONNECTIONS . . . . 5 WIRING/TERMINAL 11
DESCRIPTION AND OPERATION tions, helpful information, and system diagrams. The
intention is to organize information by system, con
HOW TO USE THIS GROUP sistently from year to year.
The purpose of this group is to show the electrical
circuits in a clear, simple fashion and to make trou CONNECTOFt/GiOUNi LOCATiOlS
bleshooting easier. Components that work together Section 8W-90 contains connector/ground location
are shown together. A l l electrical components used in illustrations. The illustrations contain the connector/
a specific system are shown on one diagram. The Teed ground number and component identification. Con
for a system is shown at the top of the page. A l l nector/ground location charts i n Section 8W-90
wires, connectors, splices, and components are shown reference the illustration number for components and
In the flow of current to the bottom of the page. Wir connectors.
ing which is not part of the circuit represented is ref Section 8W-80 shows each connector and the cir
erenced to another page/section, where the complete cuits involved with that connector. The connectors
circuit is shown. In addition, all switches, compo are identified using the number on the Diagram
nents, and modules are shown in'the at rest posi pages.
t i o n w i t h the doors closed and the key removed
from the i g n i t i o n . SPLICE LOCATiOlS
I f a component is part of several different circuits, Splice Location charts in Section 8W-70 show the
it is shown i n the diagram for each. For example, the entire splice, and provide references to other sections
headlamp switch is the main part of the exterior the splice serves.
lighting, but it also affects the Interior lighting and Section 8W-95 contains illustrations that show the
the chime warning system. I t is i m p o r t a n t to real general location of the splices In each harness. The
ize that no attempt is made on the diagrams to illustrations show the splice by number, and provide
represent components and w i r i n g as they a written location.
appear on the vehicle. For example, a short
piece of w i r e is treated the same as a long one. 10TES, CAUTIONS, and WARNINGS
I n addition, switches and other components are Throughout this group additional important infor
shown as simply as possible, w i t h r e g a r d to mation is presented In three ways; Notes, Cautions,
function only. and Warnings.
NOTES are used to help describe how switches or
SECTION IDENTIFICATION components operate to complete a particular circuit.
Sections in Group 8W are organized by sub-sys They are also used to indicate different conditions
tems. The sections contain circuit operation descrip-
8W - 01 - 2 8W - 01 GENERAL INFORMATION — — — - mi
D E S C R I P T I O N AHD O P E R A T I O N ( C o n t i n u e d )
that may appear on the vehicle. For example, an shown as a two letter code which can be identified by
up-to and after condition. referring to the Wire Color Code Chart (Fig. 2)
CAUTIONS are used to indicate information that
could prevent making an error that may damage the A 2 18 LB/YL
vehicle.
WARNINGS provide information to prevent per
sonal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a COLOR OF WIRE
vehicle is being serviced. (Light Blue with Yellow Tracer)
WARNING: ALWAYS WEAR SAFETY GLASSES FOR GAUGE OF WIRE

EYE PROTECTION. (18 Gauge)
PART OF M A I N CIRCUIT
WARNING: USE SAFETY STANDS ANYTIME A PRO (Varies Depending on Equipment)
CEDURE REQUIRES BEING UNDER A VEHICLE.
M A I N CIRCUIT IDENTIFICATION
J958W-37
WARNING: BE SURE THAT THE IGNITION SWITCH
ALWAYS IS IN THE OFF POSITION, UNLESS THE Fig, 1 Wire Code Identification
PROCEDURE REQUIRES IT TO BE ON.
STANDARD STANDARD
COLOR COLOR COLOR
TRACER COLOR TRACER
CODE CODE
WARNING: SET THE PARKING BRAKE WHEN COLOR CODE
WORKING ON ANY VEHICLE. AN AUTOMATIC BL BLUE WT OR ORANGE BK

TRANSMISSION SHOULD BE IN PARK. A MANUAL
TRANSMISSION SHOULD BE IN NEUTRAL. BK BLACK WT PK PINK BK O R WT
BR BROWN WT RD RED WT
WARNING: OPERATE THE ENGINE ONLY IN A
DB DARK WT TN TAN WT
WELL-VENTILATED AREA.
BLUE
DG DARK WT VT VIOLET WT
WARNING: KEEP AWAY FROM MOVING PARTS GREEN
WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS. GY GRAY BK WT WHITE BK
LB LIGHT BK YL YELLOW BK
WARNING: TO PREVENT SERIOUS BURNS, AVOID BLUE
CONTACT WITH HOT PARTS SUCH AS THE RADIA *

LG LIGHT BK WITH TRACER
TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA GREEN
LYTIC CONVERTER, AND MUFFLER.
918W-136
WARNING: DO NOT ALLOW FLAME OR SPARKS Fig. 2 Wire Color Code Chart
NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY. CIRCUIT IDENTIFICATION
All circuits in the diagrams use an alpha/numeric
code to identify the wire and its function (Fig. 3). To
WARNING: ALWAYS REMOVE RINGS, WATCHES, identify which circuit code applies to a system, refer
LOOSE HANGING JEWELRY, AND LOOSE CLOTH to the Circuit Identification Code Chart. This chart
ING. shows the main circuits only and does not show the
secondary codes that may apply to some models.
WIRE CODE IDENTIFICATION CONNECTORS

Each wire shown in the diagrams contains a code Connectors shown in the diagrams are identified
(Fig. 1) which identifies the main circuit, part of the using the international standard arrows for male and
main circuit, gauge of wire, and color. The color is female terminals (Fig. 4). A connector identifier is
BR 8W - 01 GENERAL INFORMATION 8W - 01 - 3
(MALE TERMINAL) (CONNECTOR

CIRCUIT FUNCTION IDENTIFICATION
NUMBER)
A Battery Feed
B Brake Controls
C Climate Controls
D Diagnostic Circuits
E Dimming Illumination Circuits (FEMALE
F Fused Circuits (Secondary Feed) TERMINAL)
G Monitoring Circuits (Gauges)
H Open
I Not U s e d 948W-191
J Open
K Powertrain Control Module Fig. 4 Connector identification
L Exterior Lighting
M Interior Lighting titles the connector by number and provides terminal
N E S A Module numbering, circuit identification, wire colors, and
O Not U s e d functions.
P Power Option (Battery Feed) All connectors are viewed from the terminal end
Q Power Options (Battery Feed) unless otherwise specified. To find the connector loca
R Passive Restraint
tion in the vehicle refer to section 8W-90. This sec
S Suspension/Steering
Transmission/Transaxle/Transfer C a s e
tion uses the connector identification number from
T
U Open
the wiring diagrams to provide a figure number ref
V S p e e d Control, Washer/Wiper erence.
W Open
X Audio Systems TAKE OUTS
Y Open The abbreviation T/O is used in the component
Z Grounds location section to indicate a point in which the wir
948W-190 ing harness branches out to a component.
Fig. 3 Circuit identification SYMBOLS

Various symbols are used throughout the Wiring
placed next to the arrows to indicate the connector
Diagrams. These symbols can be identified by refer
number (Fig. 4).
ring to the symbol identification chart (Fig. 5).
For viewing connector pin outs, with two terminals
or greater, refer to section 8W-80. This section iden-
8W - 01 - 4 8W - 01 GENERAL INFORMATION —~ BR
LEG1MD 0¥ SYMBOLS USED O N WIRING Mr^Ln^M

POSITIVE BY-DIRECTIONAL ZENER DIODE
— NEGATIVE
-O- MOTOR
GROUND
0 ARMATURE AND BRUSHES
FUSE CONNECTOR IDENTIFICATION
GANG FUSES WITH BUSS BAR -> MALE CONNECTOR
CIRCUIT BREAKER >— FEMALE CONNECTOR
CAPACITOR — 6
DENOTES WIRE CONTINUES
ELSEWHERE ;
DENOTES WIRE GOES TO ONE OF TWO
n OHMS
h ~ CIRCUITS
•AAA-* RESISTOR SPLICE
VARIABLE RESISTOR S100 SPLICE IDENTIFICATION
SERIES RESISTOR —-sffcP— THERMAL ELEMENT
1
COIL rrTl TIMER
STEP UP COIL 1
MULTIPLE CONNECTOR
' Y Y Y
OPEN CONTACT OPTIONAL WIRING WITH

WIRING WITHOUT
CLOSED CONTACT Y " Y " WINDINGS
CLOSED SWITCH BB'BB DIGITAL READOUT
— - OPEN SWITCH SINGLE FILAMENT LAMP
CLOSED GANGED SWITCH DUAL FILAMENT LAMP
:£ OPEN GANGED SWITCH L.E.D. - LIGHT EMITTING DIODE
TWO POLE SINGLE THROW SWITCH THERMISTOR
PRESSURE SWITCH GAUGE
SOLENOID SWITCH SENSOR
MERCURY SWITCH FUEL INJECTOR
-14- DIODE OR RECTIFIER
Fig. 5 Symbol Identification

BR 8W - 01 GENERAL INFORMATION 8W - 01 - 5
D E S C R I P T I O N AND O P E R A T I O N ( C o n t i n u e d )
ELECTROSTATIC DISCHARGE (ESD) SENSITIVE CAUTION: Most of the electrical components used
DEVICES in today's vehicle are solid state. When checking
All ESD sensitive components are solid state and a voltages in these circuits use a meter with a 10-me-
symbol (Fig. 6) is used to indicate this. When han gohm or greater impedance.
dling any component with this symbol comply with
• Ohmmeter - Used to check the resistance
the following procedures to reduce the possibility of
between two points of a circuit. Low or no resistance
electrostatic charge build up on the body and inad
in a circuit means good continuity.
vertent discharge into the component. I f it is not
known whether the part is ESD sensitive, assume CAUTION: - Most of the electrical components used
that it is. in today's vehicle are Solid State. When checking
(1) Always touch a known good ground before han resistance in these circuits use a meter with a
dling the part. This should be repeated while han 10-megohm or greater impedance. In addition, make
dling the part and more frequently after sliding sure the power is disconnected from the circuit.
across a seat, sitting down from a standing position, Circuits that are powered up by the vehicle electri
or walking a distance. cal system can cause damage to the equipment and
(2) Avoid touching electrical terminals of the part, provide false readings.
unless instructed to do so by a written procedure.
(3) When using a voltmeter, be sure to connect the • Probing Tools - These tools are used for probing
ground lead first. terminals in connectors (Fig. 7). Select the proper
(4) Do not remove the part from its protective size tool from Special Tool Package 6807, and insert
packing until it is time to install the part. it into the terminal being tested. Use the other end
(5) Before removing the part from its package, of the tool to insert the meter probe.
ground the package to a known good ground on the
vehicle. SPECIAL TOOL
6801
PROBING
END 948W-233
948W-193 Fig. 7 Probing Tool
Fig. 6 Electrostatic Discharge Symbol INTERMITTENT AND POOR CONNECTIONS

Most intermittent electrical problems are caused
D I A G N O S E S AMD TESTING by faulty electrical connections or wiring. I t is also
possible for a sticking component or relay to cause a
TROUBLESHOOTING TOOLS problem. Before condemning a component or wiring
When diagnosing a problem in an electrical circuit assembly check the following items.
there are several common tools necessary. These tools • Connectors are fully seated
are listed and explained below. • Spread terminals, or terminal push out
• Jumper Wire - This is a test wire used to con • Terminals in the wiring assembly are fully
nect two points of a circuit. I t can be used to bypass seated into the connector/component and locked i n
an open in a circuit. position
• Dirt or corrosion on the terminals. Any amount
WARNING: NEVER USE A JUMPER WIRE ACROSS of corrosion or dirt could cause an intermittent prob
A LOAD, SUCH AS A MOTOR, CONNECTED lem
BETWEEN A BATTERY FEED AND GROUND. • Damaged connector/component casing exposing
the item to dirt and moisture
• Voltmeter - Used to check for voltage on a cir
• Wire insulation that has rubbed through causing
cuit. Always connect the black lead to a known good
a short to ground
ground and the red lead to the positive side of the
• Wiring broke inside of the insulation
circuit.
8W - 01 - 6 8W - 01 GENERAL INFORMATION 2H
TROUBLESHOOTING TESTS
Before beginning any tests on a vehicles electrical
system use the W i r i n g Diagrams and study the cir
cuit. Also refer to the Troubleshooting W i r i n g Prob
lems section i n this section.
FUSE REMOVED
FROM CIRCUIT
TESTING FOR VOLTAGE
(1) Connect the ground lead of a voltmeter to a
known good ground (Fig. 8).
(2) Connect the other lead of the voltmeter to the
selected test point. The vehicle ignition may need to
be turned O N to check voltage. Refer to the appropri
ate test procedure.
JTX_£
X
948W-195
Fig. 9 Testing for Continuity

TESTING FOR A SHORT TO GROUND ON
FUSES POWERING SEVERAL LOADS
(1) Refer to the w i r i n g diagrams and disconnect or
isolate all items on the fused circuit.
(2) Replace the blown fuse.
(3) Supply power to the fuse by t u r n i n g O N the
ignition switch or re-connecting the battery.
(4) Start connecting the items i n the fuse circuit
one at a time. When the fuse blows the circuit w i t h
the short to ground has been isolated.
948W-194
TESTING FOR A VOLTAGE DROP
Fig. 8 Testing for Voitage (1) Connect the positive lead of the voltmeter to
the side of the circuit closest to the battery (Fig. 10).
TESTING FOR CONTINUITY
(2) Connect the other lead of the voltmeter to the
(1) Remove the fuse for the circuit being checked
other side of the switch or component.
or, disconnect the battery.
(3) Operate the item.
(2) Connect one lead of the ohmmeter to one side
(4) The voltmeter w i l l show the difference i n volt
of the circuit being tested (Fig. 9).
age between the two points.
(3) Connect the other lead to the other end of the
circuit being tested. Low or no resistance means good
TROUBLESHOOTING WIRING PROBLEMS
continuity.
When troubleshooting w i r i n g problems there are
TESTING FOR A SHORT TO GROUND six steps which can aid i n the procedure. The steps
(1) Remove the fuse and disconnect all items are listed and explained below. Always check for non-
involved w i t h the fuse. factory items added to the vehicle before doing any
(2) Connect a test light or a voltmeter across the diagnosis. I f the vehicle is equipped w i t h these items,
terminals of the fuse. disconnect them to verify these add-on items are not
(3) Starting at the fuse block, wiggle the w i r i n g the cause of the problem.
harness about six to eight inches apart and watch (1) Verify the problem.
the voltmeter/test lamp. (2) Verify any related symptoms. Do this by per
(4) I f the voltmeter registers voltage or the test forming operational checks on components t h a t are
lamp glows, there is a short to ground i n t h a t gen i n the same circuit. Refer to the w i r i n g diagrams.
eral area of the w i r i n g harness.
BR 8W - 01 GENERAL INFORMATION 8W - 0 1 - 7
(8) Center the heat shrink tubing over the joint,
and heat using a heat gun. Heat the joint until the
+ tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(9) Secure the wire to the existing ones to prevent
chafing or damage to the insulation
(10) Connect battery and test all affected systems.
948W-196
Fig. 10 Testing for Voltage Drop

(3) Analyze the symptoms. Use the wiring dia
grams to determine what the circuit is doing, where
the problem most likely is occurring and where the
diagnosis will continue.
(4) Isolate the problem area.
(5) Repair the problem.
(6) Verify proper operation. For this step check for Fig. 11 Wire Repair
proper operation of all items on the repaired circuit.
Refer to the wiring diagrams. TERMINAL/CONNECTOR REPAIR-MOLEX
CONNECTORS
(1) Disconnect battery.
SERVICE PROCEDURES (2) Disconnect the connector from its mating half/
component.
WIRING REPAIR (3) Insert the terminal releasing special tool 6742
When replacing or repairing a wire, i t is important into the terminal end of the connector (Fig. 12).
that the correct gauge be used as shown in the wir
ing diagrams. The wires must also be held securely CONNECTOR
in place to prevent damage to the insulation. \
(1) Disconnect battery negative cable
(2) Remove 1 inch of insulation from each end of
the wire.
(3) Place a piece of heat shrink tubing over one
side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area.
(4) Spread the strands of the wire apart on each
part of the exposed wire (example 1). (Fig.' 11)
(5) Push the two ends of wire together until the
strands of wire are close to the insulation (example
2) (Fig. 11)
(6) Twist the wires together (example 3) (Fig. 11) SPECIAL TOOL
6742 948W-234
(7) Solder the connection together using rosin core
type solder only. Do not use acid core solder.
Fig. 12 Molex Connector Repair
8W - 01 - 8 8W - 01 GENERAL INFORMATION BR

(4) Using special tool 6742 release the locking fin
gers on the terminal (Fig. 13).
(5) Pull on the wire.to remove i t from the connec
tor.
(6) Repair or replace the connector or terminal, as
necessary.
Fig. 13 Using Special Tool 6742

TERMINAL/CONNECTOR REPAIR—THOMAS AND
BETTS CONNECTORS
(2) Disconnect the connector from its mating half/
component.
(3) Push in the two lock tabs on the side of the
connector (Fig. 14).
803f588c
Fig. 16 Single Lock Tab

CONNECTOR REPLACEMENT
(2) Disconnect the connector that is to be repaired
from its mating half/component
(3) Remove the connector locking wedge, i f
required (Fig. 17)
(4) Position the connector locking finger away from
the terminal using the proper pick from special tool
kit 6680. Pull on the wire to remove the terminal
from the connector (Fig. 18) (Fig. 19).
Fig. 14 Thomas and Betts Connector Lock Release (5) Reset the terminal locking tang, i f i t has one.
Tabs (6) Insert the removed wire in the same cavity on
(4) Insert the probe end of special tool 6934 into the repair connector.
the back of the connector cavity (Fig. 15). (7) Repeat steps four through six for each wire in
(5) Grasp the wire and tool 6934 and slowly the connector, being sure that all wires are inserted
remove the wire and terminal from the connector. into the proper cavities. For additional connector pin-
(6) Repair or replace the terminal.- out identification, refer to the wiring diagrams.
(7) Install the wire and terminal in the connector. (8) Insert the connector locking wedge into the
Fully seat the terminal in the connector. repaired connector, i f required.
8W - 01 GENERAL INFORMATION 8W - 01 - S
CONNECTOR CONNECTOR AND TERMINAL REPLACEMENT

(2) Disconnect the connector (that is to be
repaired) from its mating half/component.
(3) Cut off the existing wire connector directly
behind the insulator. Remove six inches of tape from
the harness.
( 4 ) Stagger cut all wires on the harness side at
1/2 inch intervals (Fig. 20).
(5) Remove 1 inch of insulation from each wire on
the harness side.
(6) Stagger cut the matching wires on the repair
connector assembly in the opposite order as was done
on the harness side of the repair. Allow extra length
CONNECTOR LOCKING
928W-143 for soldered connections. Check that the overall
WEDGE TAB
length is the same as the original (Fig. 20).
Fig. 17 Connector Locking Wedge
REPAIR SIDE STAGER CUTS
(9) Connect connector to its mating half/compo WIRES
nent.
(10) Connect battery and test all affected systems.
HARNESS WIRES 928W-145
Fig. 20 Stagger Cutting Wires

FROM (7) Remove 1 inch of insulation from each wire.
SPECIAL TOOL
KIT 6680 948W-236 (8) Place a piece of heat shrink tubing over one
side of the wire. Be sure the tubing will be long
Fig. 18 Terminal Removal enough to cover and seal the entire repair area.
part of the exposed wires.
strands of wire are close to the insulation.
(11) Twist the wires together.
(12) Solder the connection together using rosin
core type solder only. Do not use acid core solder.
(13) Center the heat shrink tubing over the joint
tubing is tightly sealed and sealant comes out of both
ends of the tubing
(14) Repeat steps 8 through 13 for each wire.
(15) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
CONNECTOR 948W-237 (16) Re-connect the repaired connector.
(17) Connect the battery, and test all affected sys
tems.
Fig. 19 Terminal Removal Using Special Tool
8W - 01 GENERAL INFORMATION
8w - 01 - n
TERMINAL REPLACEMENT
(2) Disconnect the connector being repaired, from
its mating half. Remove connector locking wedge, i f
required (Fig. 21).
. (3) Remove connector locking wedge, i f required
(Fig. 21).
CONNECTOR
CONNECTOR 948W-237
Fig. 23 Terminal Removal Using Special Tool

(9) Place a piece of heat shrink tubing over one
side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area.
CONNECTOR LOCKING part of the exposed wires.
928W-143
WEDGE TAB
Fig. 21 Connector Locking Wedge Tab (Typical) part of the exposed wires.
(4) Position the connector locking finger away
strands of wire are close to the insulation.
from the terminal using the proper pick from special
(13) Twist the wires together.
tool k i t 6680. Pull on the wire to remove the terminal
(14) Solder the connection together using rosin
from the connector (Fig. 22) (Fig. 23).
core type solder only. Do not use acid core solder.
(15) Center the heat shrink tubing over the joint
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(16) Insert the repaired wire into the connector.
(17) Install the connector locking wedge, i f
required, and reconnect the connector to its mating
half/component.
(18) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
(19) Connect battery, and test all affected systems.
DIODE REPLACEMENT
FROM
SPECIAL TOOL (1) Disconnect the battery.
KIT 6680 948W-236 (2) Locate the diode in the harness, and remove
the protective covering.
Fig. 22 Terminal Removal (3) Remove the diode from the harness, pay atten
(5) Cut the wire 6 inches from the back of the tion to the current flow direction (Fig. 24).
connector. (4) Remove the insulation from the wires in the
(6) Remove 1 inch of insulation from the wire on harness. Only remove enough insulation to solder in
the harness side. the new diode.
(7) Select a wire from the terminal repair assem (5) Install the new diode in the harness, making
bly that best matches the color wire being repaired. sure current flow is correct. I f necessary refer to the
(8) Cut the repair wire to the proper length and appropriate wiring diagram for current flow.
remove 1 inch of insulation. (6) Solder the connection together using rosin core
type solder only. Do not use acid core solder.
BR — — 8W - 01 GENERAL 0I1AT10N • • 8W - 01 -11
SPECIAL TOOLS
<^BI CURRENT FLOW
WIRING/TERMINAL
BAND A R O U N D DIODE
INDICATES CURRENT FLOW
— N
DIODE AS S H O W N I N
THE DIAGRAMS
948W-197 Terminal Removing Tool 6934
Fig. 24 Diode Identification

(7) Tape the diode to the harness using electrical
tape making, sure the diode is completely sealed
from the elements.
(8) Re-connect the battery, and test affected sys
tems.
Probing Tool Package 6807
Terminal Pick 6680
Terminal Removing Tool 6932

8W - 02 COMPONENT INDEX 8W - 02 -1
8W-02 COMPONENT INDEX
G E N E R A L INFORMATION on system operation, refer to the appropriate section

of the wiring diagrams.
INTRODUCTION
This section provides an alphabetical listing of all
the components covered in group 8W. For information
8W -12 - 2 8W-02 COMPONENT INDEX BR
COMPONENT INDEX
Component Section Component Section
A/C Compressor Clutch 8W-42 Front Wheel Speed Sensors 8W-35

A/C Compressor Clutch Relay ... 8W-11,42 Fuel Heater... 8W-30
A/C High Pressure Cutout Switch 8W-42 Fuel Heater Relay .8W-30
A/C Low Pressure Cutout Switch 8W-42 Fuel Pump Module 8W-30
A/C-Heater Control Switch .8W-42 Fuel Pump Relay 8W-11,30
ABS 2-Way Power Feed 8W-35 Fuel Shut Down Relay 8W-30
ABS Pump Motor Relay 8W-11, 35 Fuel Shut Down Solenoid 8W-30
ABS Warning Lamp Relay . . . . . . . . . . . . . . . . . . . . . 8W-11, 35 Fuse Block. 8W-10
Airbag Control Module 8W-43 Fuse Block Relay Charts 8W-10
Ambient Temperature Sensor 8W-49 Generator 8W-10
Automatic Shut Down Relay 8W-11, 30 Glove Box Lamp/Switch 8W-44
Back-Up Lamp Switch 8W-51 Ground Joint 8W-15
Back-Up Lamps 8W-51 Hazard Warning Flasher 8W-52
Battery SW-20 Headlamp Dimmer Switch .8W-11, 50
Battery Temperature Sensor 8W-30 Headlamp Switch
Blower Motor 8W-42 .8W-10,11,12, 31, 40, 42, 44, 47, 49, 50, 51
Blower Motor Resistor Block 8W-42 Headlamps 8W-50
Brake Switch 8W-34, 35, 40 Heated Intake Air System . . . . . . . . . . . . . . 8W-30
Buzzer Module 8W-44 Heated Intake Air System Relay 1 . . . . . . . . . . . . . . . . . . 8W-30
Bypass J u m p e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11, 21 Heated Intake Air System Relay 2 8W-30
Camshaft Position Sensor 8W-30 Heated Oxygen Sensors 8W-30
Cargo Lamps 8W-44 Heater Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42
Center High Mounted Stop Lamps ( C H M S L ) . . . . . . . . . 8W-51 Horn Relay 8W-11,41
Center Identification Lamp 8W-50 Horns 8W-41
Cigar Lighter 8W-41 Hydraulic Control Unit 8W-35
Clutch Pedal Position Switch .8W-11, 21 Idle Air Control Motor 8W-30
Controller Anti-Lock B r a k e . . . . . . . . . . . . . . . . . . . . 8W-34, 35 Ignition Coil 8W-30
Crankshaft Position Sensor 8W-30 Ignition Coil 4-Pack (8.0L ENG) 8W-30
Data Link Connector 8W-30 Ignition Coil 6-Pack (8.0L ENG) 8W-30
Day/Night Mirror 8W-44 Ignition Switch 8W-3Q
Daytime Running Lamp Module 8W-50 Injectors (3.9L E N G ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Dome Lamp 8W-44 Injectors (5.2L/5.9L ENG) 8W-30
Driver Side Airbag 8W-43 Injectors (8.0L E N G ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Duty Cycle Evap/Purge Solenoid 8W-30 Instrument Cluster 8W-40
EGR Control Module 8W-30 Intake Air Temperature Sensor 8W-30
EGR Engine Coolant Temperature Sensor 8W-30 Intermittent Wiper Control Module 8W-53
EGR Intake Air Temperature Sensor 8W-30 Intermittent Wiper Switch 8W-53
Engine Coolant Temperature Sending U n i t . . . . . . . . . . . 8W-40 Joint Connectors A, B, and C 8W-12
Engine Coolant Temperature Sensor 8W-30 Key-ln-Switch/Halo Lamp 8W-44
Engine Oil Pressure Sensor 8W-40 Left Airbag Sensor 8W-43
Engine Speed Sensor 8W-30 Left Door Jamb Switch 8W-49
Engine Starter Motor 8W-21 Left Door Premium Speaker 8W-61
Engine Starter Motor Relay 8W-11, 21 Left Door Speaker 8W-47
Exhaust Gas Recirculation Solenoid 8W-30 Left Door Tweeter 8W-47
Fog Lamp Relay No. 1 8W-11, 50 Left Power Door Lock M o t o r . . . . . . . . . . . . . . . . . . . . . . 8W-47
Fog Lamp Relay No. 2 8W-11, 50 Left Power Door Lock Switch 8W-61
Fog Lamp Switch 8W-50 Left Power Mirror Motors 8W-62
Fog Lamps 8W-50 Left Power Window Motor .8W-60
Forward/Backward Seat M o t o r . . . . . . . . . . . . . . . . . . . . 8W-63 Left Power Window Switch 8W-60
Forward Fender Lamps 8W-51 Left Rear Premium Speaker 8W-47
Four Wheel Drive (4WD) Switch 8W-31,34, 35, 40 Left Rear S p e a k e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Front Up/Down Seat Motor 8W-63 License Lamps 8W-51
3040bfeb J968W-9
BR — — — ^ 8W-02 COMPONENT INDEX 8W - 02 - 3
COMPONENT INDEX
Component Section Component Section
Low Washer Fluid Switch 8W-53 Right Power Mirror Motors 8W-62
Manifold Absolute Pressure .. 8W-30 Right Power Window Motor 8W-60
Message Center . . . . 8W-46 Right Power Window Switch 8W-60
Outboard Clearance Lamps — . — 8W-50 Right Rear Premium S p e a k e r . . . . . . . . . . . . . — . . . . 8W-47 •
Outboard Identification Lamps 8W-50 Right Rear Speaker 8W-47
Overdrive Switch 8W-31 RWAL V a l v e . . . . . . . . 8W-34, 35
Overhead Console 8W-49 Seat Belt Switch 8W-44
Overhead Map/Courtesy Lamp — 8W-49 Stop Lamp Switch 8W-33, 34, 35, 51, 52
Park Brake Switch 8W-34 Tail, Stop and Turn Signal Lamps 8W-51, 52
Park/Neutral Position Switch 8W-11, 21, 51 Tailgate Lamps . . . . — • 8W-51
Park/Turn Signal Lamps 8W-50, 52 Throttle Position S e n s o r . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
PDC Relay Charts 8W-11 Time Delay Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44
Power Distribution Center • • 8W-11 Trailer Brake Provision — 8W-54
Power Mirror Switch • 8W-62 Trailer Tow 8W-54
Power Outlet • •• 8W-41 Trailer Tow Relay 8W-11.54
Power Seat Switch 8W-63 Transmission Output Shaft Speed Sensor 8W-31
Powertrain Control Module 8W-30 Transmission Relay 8W-11,31
Radio 8W-47 Transmission Solenoid Assembly — .. — . . . . . . . . 8W-31
Radio Choke 8W-47 Turn Signal F J a s h e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52
Rear Fender Lamps • • • 8W-51 Turn Signal/Hazard Switch 8W-50, 52
Rear/Vertical Seat Motor •. 8W-63 Underhood Lamp 8W-44
Rear Wheel Speed Sensor 8W-34, 35 Vacuum Sensor 8W-34, 35
Right Airbag Sensor. 8W-43 Vehicle Speed Control/Horn Switch 8W-33,41
Right Door Jamb Switch • • • 8W-49 Vehicle Speed Control Servo 8W-33
Right Door Premium Speaker — . — 8W-61 Vehicle Speed Sensor 8W-30
Right Door Speaker 8W-47 Visor/Vanity Lamps 8W-44
Right Door Tweeter 8W-47 Water-in-Fuel Sensor 8W-30
Right Power Door Lock M o t o r . . . . . . . . . . . . . . . . . . . . 8W-47 Windshield Washer Pump Motor 8W-53
Right Power Door Lock Switch . . . . . . . . . . . . . . . . . . . . 8W-61 Windshield Wiper Motor 8W-53
J968W-9
8040bfec
BR — 8W - 10 FUSE/FUSE BLOCK — — — 8W - 10 -1
8W-10 FUSE/FUSE BLOCK
INTRODUCTION
This section covers the Fuse Block and all circuits
involved with it. For additional information on sys
tem operation, refer to the appropriate section of the
wiring diagrams.
8W-10-2- 8W-10 FUSE/FUSE BLOCK mm
DIAGRAM INDEX
Component Page Component ^ Page
Airbag Control Module 8W-10-7, 9 Fuse 16. .... 8W-10-9
Circuit Breaker 1 8W-10-9 Fuse 17 8W-10-10
Controller Anti-Lock Brake 8W-10-8 Fuse 19 8W-10-12
Fusel 8W-10-5, 6, 7 Fuse 20 - 8W-10-12
Fuse 1 (PDC) 8W-10-5,10,11,12 Fuse Block .8W-10-3
Fuse 2 (PDC) 8W-10-8, 9 Fuse C h a r t . . . . . . . . . . . . . . . . . . . 8W-10-4
Fuse 3 (PDC) , 8W-10-5, 6, 7 F2 8W-10-9
Fuse 5 8W-10-5 Headlamp Switch 8W-10-11
Fuse 6 8W-10-5 Ignition Switch 8W-10-5, 6, 7, 8, 9
Fuse 6 (PDC) 8W-10-12 Instrument Cluster 8W-10-7
Fuse 7 8W-10-5 Joint Connector A 8W-10-11
Fuse 8 8W-10-5 Joint Connector B 8W-10-10,12
Fuse 9 8W-10-6 Joint Connector C 8W-10-7, 9,11
Fuse 11 8W-10-7 Overhead Console 8W-10-10
Fuse 12 8W-10-7 Powertrain Control Module 8W-10-6
Fuse 13 8W-10-11 Radio 8W-10-5
Fuse 14 8W-10-8 Relay Charts ...............8W-10-4
Fuse 15 8W-10-9
8040bfed J968W-9
BR 8W-10 FUSE/FUSE BLOCK 8W-10-3
\ /
F U S E BLOCK
C241
8040bfee J968W-9
8 W . -, o . 4 — — — — 8W-10 FUSE/FUSE BLOCK — — — — BR
FUSE AMPS COLOR SECTION/PAGE

1 20 YELLOW 8W-10-5
2 _ -
3 - _
4 - - _
5 20 YELLOW 8W-10-5
6 15 LIGHT BLUE 8W-10-5
7 15 RED ......... 8 W - 1 0 - 5
8 20 YELLOW 8W-10-5
Q in RF n 8w-m-fi
in
10 REn 9W-10-7
1
2 i 5 L I G H T BLUE 8W-10-7
13 5 ! 1 8W-10-11
14 20 —
—
——
— ————
- ™YELLOW
—— t'rs
-lrt— ^M
iIc
e
—
frf ™ — 8W-10-8
15 10 TAN
RED 8W-10-9
19 20 YELLOW 8W-10-12
F1
F2 30 GRPFN 8W-10-9
C I R C U I T BREAKER 8W-10-9
-XB2- W CIRCUIT-4S&EAKER 8W-10^-5
TURN CAV CIRCUIT FUNCTION SECTION/PAGE

SIGNAL 1 L6 20RD/GY TURN SIGNAL FLASHER OUTPUT 8W-52-3
FLASHER 2 L5 20BK FUSED IGNITION SWITCH OUTPUT (ACC/RUN) 8W-52-3
HAZARD CAV CIRCUIT FUNCTION SECTION/PAGE

WARNING 3 L19 18PK/WT HAZARD FLASHER OUTPUT 8W-52-3
FLASHER 4 L9 18BK/VT FUSED B ( + ) 8W-52-3
CAV CIRCUIT FUNCTION SECTION/PAGE

TIME 53 M2 22YL COURTESY LAMPS DRIVER 8W-44-4.5
DELAY 54 M50 2 2 Y L / R D K E Y - I N LAMP DRIVER 8W-44-4.5
RELAY 55 Ml 20PK FUSED B( + ) 8W-44-4.5
8040bfef J968W-9
BR' 8W-10 FUSE/FUSE BLOCI 8W-10-5
•AO 6RD-
BATTERY
POSITIVE
TERMINAL
<8W-20-3,4)
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH D I E S E L
ENG)
(8W-20-4)
C303
POWER POWER
OUTLET SEAT
(8W-41-3) SWITCH
(8W-53-4) (8W-63-3)
INTERMITTENT INTERMITTENT
WIPER WIPER
SWITCH CONTROL
(8W-53-3) MODULE * WITH GAS ENG
CAVITY 3 ** WITH DIESEL ENG
(8W-53-3,4)
8040bff0 J968W-9
8W-10-6- 8W-10 FUSE/FUSE BLOCK BR
•AO 6RD-
BATTERY
POSITIVE
TERMINAL
(8W-20-3.4)
POWER
AO AO AO DISTRIBUTION
OERD 6RD* 20BK* CENTER
RIGHT
FUSE
I I 3
BATTERY AO AO 40A
POSITIVE
TERMINAL
(WITH DIESEL
J OOERD** 14PK**
(3) ^ €180
ENG) ENGINE SPLICE

(8W-20-4)
STARTER S148
MOTOR C8W-7Q-21)
<8W-21-3 4)
P
FUEL FUEL HEATED HEATED

PUMP SHUT INTAKE INTAKE
F18
RELAY DOWN A I R SYSTEM A I R SYSTEM
22LG
C8W-3©-2@,41) BK SOLENOID R E L A Y NO. I R E L A Y NO. 2
(8W-11-11) (8W-30-47) (8W-30-48) (8W-30-48)
WITH
DIESEL ENG
A/C
COMPRESSOR FUEL
CLUTCH HEATER
RELAY RELAY
(8W-42-8) (8W-30-47)
C8W-11-8)
WITH
5.2L AND
5.9L ENG
TRANSMISSION AUTOMATIC DUTY C Y C L E EXHAUST

RELAY S H U T DOWN EVAP/PURGE GAS
(8W-31-4) RELAY >[< C 1 3 5 SOLENOID RECIRCULATION
(8W-11-9) (8W-30-12) (8W-30-20) SOLENOID
A2 POWERTRAIN
(8W-11-10) (8W-30-20)
CONTROL
FUSED
'MODULE
IGN SW
INPUT
(START/ * WITH GAS ENG
RUN) ** WITH DIESEL ENG
8040bffl J968W-9
mm -— — - - 8W-10 FUSE/FUSE BLOCK —- 8W-10-7
AO 6RD
BATTERY
POSITIVE
TERMINAL
(8*4-20-3,4)
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH DIESEL
ENG)
(8W-20-4)
MESSAGE
CENTER
(8W-46-3)
WITH GAS ENG
WITH DIESEL ENG
8040bff2 J968W-9
8W-1G-S' 8W-10 FUSE/FUSE BLOCK •BR
AO 6RD
BATTERY
POSITIVE
TERMINAL
<8W-20-3„4)
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH DIESEL
ENG) ENGINE SPLICE
CSW-20-4) STARTER S148
MOTOR (8W-70-21)
(8W-21-3,4)
FUSE BLOCK
IGNITION
SWITCH
S201
C212
8W-70-26
-)>—-A2 12PK/BK
| — A22 12BK/0R-
(4)
A22
12BK
OR
CONTROLLER ABS
ANTI-LOCK WARNING
(23): C241 FUSED IGNITION BRAKE LAMP
SWITCH OUTPUT (ABS) RELAY
FUSE (RUN) (8W-35-6)
14 1 (8W-11-16)
20A A20
1
! 6 7 12 17 21 ! 1
(26): C241 18RD

C121 DB
A20
18RD ABS
DB A20 A20 A20 A20 A20 PUMP
18RD 18RD 18RD 18RD 18RD MOTOR
DB DB DB DB DB I—A20 18RD/DB RELAY
(8W-35-6)
WITH (8W-11-16)
RWAL
\ A20
18RD
DB C133
A20 -A20 18RD/DB A20 18RD/DB- VACUUM
18RD SENSOR
DB SllO (WITH
C133 8W-70-6 DIESEL ENG)
-A20 18RD/DB—(f- -A20 18RD/DB- (8W-34-4)
(8W-35-5)
C228
WITH
3 CONTROLLER RWAL
FUSED ANTI-LOCK
IGNITION BRAKE
SWITCH (RWAL)
OUTPUT * WITH GAS ENG
(RUN) ** WITH DIESEL ENG
8040bff3 J968W-9
BR- 8W-10 FUSE/FUSE BLOCK 8W-1I-I
AO 6RD ^ ^
BATTERY
POSITIVE
TERMINAL
(8W-20-3,4)
POWER
DISTRIBUTION
FUSE CENTER
RIGHT 2
BATTERY 40A
POSITIVE €180
TERMINAL Y
(WITH DIESEL ENGINE SPLICE A2
ENG) STARTER S148 12PK
(8W-20-4) MOTOR C8W-70-21) BK
(8W-21-3.4) S146
8W-70-20
] IGNITION
SWITCH A2
12PK
€211 €133 BK
-)) A2 12PK/BK (£-
(4) RIGHT POWER
WINDOW SWITCH
(8W-60-4)
, OPTIONAL
FUSE
S201
8W-70-26 -A22 12BK/0R-
BLOCK Y
F21
A22 -A22 12BK/0R- 14TN
12BK
OR F21 C345
14TN
(23)^"" (11) (7): €241 F21
14TN
K F U S E S F U S E
C 15 C 16 CB1
• 10A • 15A f 3 0 A
J 30A
(27) (28) ; (12) (8): €241
CI F21
L10 F23 12DG 14TN F21
22BR 18DB
14TN
LG YL
S214
8W-70-32
BLOWER
MOTOR C239
€232 <8W-42-4,5)
- F 2 1 14TN (£—
F21
2 AIRBAG 14TN
FUSED CONTROL OPTIONAL
IGNITION MODULE €207
SWITCH
OUTPUT
(RUN) F21
14TN
r €347
- F 2 1 1 4 T N — « — F 2 1 14TN L, LEFT POWER
(28): C209 WINDOW
FUSED JOINT SWITCH
IGNITION CONNECTOR (8W-60-3)
SWITCH € -F21 14TN-
OUTPUT
(RUN) * WITH GAS ENG
* * WITH DIESEL ENG
8040bff4 J968W-9
8W-10-1Q 8W-10 FUSE/FUSE BLOCK BR
BATTERY •AO 6RD- n
POSITIVE " POWER
TERMINAL C180
DISTRIBUTION
<8W-20-3,4) FUSE 1 CENTER
AO
AO 20BK* 50A
AO 6RD* (1) A7
i i
OERD AO AO 10RD
RIGHT OOERD** 14PK** BK
S147
BATTERY
8W-70-21
POSITIVE
TERMINAL
(WITH DIESEL
J ENGINE SPLICE
S148 WITH
STARTER POWER
ENG) MOTOR C8W-70-21)
(8W-20-4) SEAT
(8W-21-3.4)
S204
C353
RIGHT VISOR/
VANITY LAMP
C8W-44-4)
CARGO CARGO POWER • WITH OVERHEAD

LAMP LAMP DOME MIRROR CONSOLE
NO. 1 NO. 2 LAiP Ml 2 0 P K — •
SWITCH * WITH GAS ENG
C8W-44-5) (8W-44-5) (8W-44-5) C8W-62-3) * * WITH DIESEL ENG
8040bff5 J968W-9
1
BR 8W-10 FUSE/FUSE BLOCK 8W-10-11
BATTERY
POSITIVE
AO 6RD- POWER
TERMINAL DISTRIBUTION
(8W-20-3,4) 1 ! I FUSE ; sm CENTER
AO FUSE x
AO
AO
6RD*
20BK*
I
| I 50A ( i ) A7
OERD AO 10RD
AO 14PK**
OOERD** BK
. RIGHT S147
' BATTERY
8W-70-21[ #
POSITIVE
TERMINAL ENGINE SPLICE
(WITH DIESEL STARTER S148 WITH
POWER A7
ENG) MOTOR C8W-70-21) 12RD
SEAT
(8W-20-4) <8W-21-3,4) BK
S204
C133
8W-70-28 A7 12RD/BK 1
I •A7 12RD/BK-«—
A7
12RD -A7 12RD/BK
BK
JOINT JOINT
FUSED CONNECTOR CONNECTOR
PANEL C A
LAMPS
DIMMER
SWITCH
SIGNAL
(5): C209
R E F TO
OVERDRIVE
SWITCH
ILLUMINATION
LAMP
(8W-31-7) FOG LAMP
SWITCH
(8W-50-10)
WITH
FOG * WITH GAS ENG
LAMPS ** WITH DIESEL ENG
8040bff6 J968W-9
8W 10-12 8W-10 FUSE/FUSE BLOCK BR
AO 6RD
BATTERY
POSITIVE
TERMINAL
C8W-20-3.4)
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH D I E S E L ENGINE SPLICE
ENG) STARTER S148
C8W-20-4) MOTOR C8W-70-21)
C8W-21-3.4)
LEFT POWER DOOR RIGHT POWER DOOR

LOCK. SWITCH LOCK SWITCH
C8W 61-3) (8W-61-4)
•
F35
F35
14RD
16RD
F35
T
F35
14RD
16RD
F35 F35
14RD C348 C346 16RD
F35 F35
0 P A L
14RD ™! 16RD
1 JOINT
! CONNECTOR
i B
; FUSED ;
• ! (B+) ;
F35 F35
14RD
S216
16RD (4) ^ k C231
C207 C239 A3
8W-70-33 12RD
F35 _ F35 F32 LG
16RD 16RD 18PK
F35 DB
16RD
C133
FUSE
(19) (20) C241 BLOCK
FUSE N FUSE A3 A7
4'
19 C 2 0
12RD 12RD
20A s
15A LG BK
(16) : C241
(14) ^
S203
•A3 12RD/LG- 8W-70-27
* WITH GAS ENG

** WITH D I E S E L ENG
8040bff7 J968W-9
8W - 11 POWER DISTRIBUTION 8W - 11 -1
8W-11 POWER DISTRIBUTION
INTRODUCTION
This section covers the power distribution center
and all circuits involved with it. For additional infor
mation on system operation, refer to the appropriate
section of the wiring diagrams.
8W-11 - 2 8W-11 POWER DISTRIBUTION BR
DIAGRAM INDEX
Component Page Component Page
A/C Compressor Clutch Relay 8W-11-8 Fuse 11 8W-11-19

ABS Pump Motor Relay 8W-11-16 Fuse 12 8W-11-19
ABS Warning Lamp Relay 8W-11-16 Fuse 14 8W-11-15,18
Automatic Shut Down Relay 8W-11 -10 Fuse 15 8W-11-18
Bypass Jumper 8W-11-17 Fuse 16 8W-11-18
Circuit Breaker 2 8W-11-18 Fuse 18 8W-11-13.18
Clutch Pedal Position Switch 8W-11-17 Fuse 19 8W-11-18
Controller Anti-Lock Brake 8W-11-15,16 Fuse 20 8W-11-14
Daytime Running Lamp Module 8W-11-14 Fuse A (PDC) 8W-11-12
Duty Cycle Evap/Purge Solenoid 8W-11-11 Fuse B (PDC) 8W-11-7.8
Engine Starter Motor Relay 8W-11-17 Fuse C (PDC) 8W-11-18
Exhaust Gas Recirculation Solenoid 8W-11-11 Fuse (Gen) (PDC) 8W-11-19
Fog Lamp Relay No. 1 8W-11-13,14 F2 8W-11-18
Fog Lamp Relay No. 2 8W-11-12 Headlamp Dimmer Switch 8W-11-14
Fuel Pump Relay 8W-11-11 Headlamp Switch 8W-11-13,14
Fusel (PDC) 8W-11-7, 8,12,13,18 Horn Relay 8W-11-7
Fuse 2 (PDC) 8W-11-.15 17,18 Ignition Switch 8W-11-8, 9,10,11,15,17,18,19, 20
Fuse 3 (PDC) 8W-11-8, 9,10,11,17,19, 20 Instrument Cluster 8W-11-16
Fuse 4 (PDC) 8W-11-10 Joint Connector A 8W-11-6,13
Fuse 5 8W-11-19 Park/Neutral Position Switch 8W-11-17
Fuse 5 (PDC) 8W-11-16 PDC Fuse Charts 8W-11-3
Fuse6 8W-11-19 PDC Relay Charts 8W-11-4, 5
Fuse 6 (PDC) 8W-11-14 Power Distribution Center 8W-11-3
Fuse 7 8W-11-19 Powertrain Control Module 8W-11-8, 9,10,11, 22
Fuse 7 (PDC) 8W-11-6 Trailer Tow Relay 8W-11-6
Fuse 8 8W-11-19 Transmission Relay 8W-11-9
Fuse 8 (PDC) 8W-11-9.11 Transmission Solenoid Assembly 8W-11-9
Fuse 9 8W-11-8.9,10,11,19,20
8040bff8 J968W-9
BR 8W-11 POWER DISTRIBUTION 8W-11 -
POWER DISTRIBUTION CENTER

C180
<M C
C M
DC
C M
rO
H
O
IV
Bl
J
J
TRAILER
I I I—I I—I i—i
HD/LP
_J
<^> h
F6
F7
00 U J
^ < y_ ID 00 J Loo
y_ 00 J
I I I I I I I I
r o
I co
fl
: ; ;
,
r -§§ 2 2 *
H Q£ U
^5
- -H
l
LL. <
QL
CAV CIRCUIT AMPS FUNCTION SECTION/PAGE

1 A7 10RD/BK 50 FUSED B(+) 8W-11-7.8.12.13.18
2 A2 12PK/BK 40 FUSED B(+) 8W-11-15,17,18
3 Al 12RD 40 FUSED B(+) 8W-11-8,9,10,11,17.19,20
4 A16 14GY/WT 30 FUSED B(+) 8W-11-I0
FUSE 5 A10 12RD/DG 40 FUSED B( + ) 8W-11-16
6 A3 12RD/LG 40 FUSED B(+) 8W-11-14
A6 12RD/TN 40 FUSED B(+) 8W-11-6
7
A6 12RD/TN 40 FUSED B ( + ) 8W-11-6
A14 16RD/WT 20 FUSED B( + ) 8W-ll-9.il
8
A14 16RD/WT 20 FUSED B(+) 8W-ll-9.il

FUSE A Al A7 12RD/BK FUSED B( + ) 8W-11-12
15
A2 L38 20LB/BK FUSED B(+) 8W-11-12

FUSE B Bl A7 12RD/BK FUSED B(+) 8W-11-7.8
20
B2 F31 18VT FUSED B(+) 8W-11-7.8

FUSE C CI A15 16PK 1 c; FUSED B(+) 8W-11-18
I D
C2 L9 18BK/VT FUSED B(+) 8W-11-18
CAV f CIRCUIT AMPS FUNCTION SECTION/PAGE

FUSE
(GEN) - A l l 6BK/GY 120 FUSED B(+) 8W-11-19
8040bff9 J968W
8W 11 - 4 BR

ENGINE 30 A2 1 2 P K / B K FUSED B(+) 8W-11-17
STARTER 85 T41 22BK/WT ENGINE STARTER MOTOR RELAY CONTROL 8W-11-17
MOTOR
RELAY 86 T141 14YL/RD ENGINE STARTER MOTOR DRIVER 8W-11-17
87 T40 12BR ENGINE STARTER MOTOR RELAY OUTPUT 8W-11-17

30 A10 12RD/DG FUSED B(+) 8W-11-16
ABS
PUMP 85 B116 20GY ABS PUMP MOTOR RELAY CONTROL 8W-11-16
MOTOR A20 18RD/DB FUSED I G N I T I O N SWITCH OUTPUT (RUN) 8W-11-16
RELAY 86
A20 18RD/DB FUSED I G N I T I O N SWITCH OUTPUT (RUN) 8W-11-16
87 B120 12BR/WT ABS PUMP MOTOR RELAY OUTPUT 8W-11-16

30 G19 2 0 L G / R D ABS WARNING LAMP RELAY OUTPUT 8W-11-16
85 B47 2 0 R D / L B ABS WARNING LAMP RELAY CONTROL 8W-11-16
86 A20 18RD/DB FUSED IGNITION SWITCH OUTPUT (RUN) 8W-11-16
A87 11 20BK GROUND SW-11-16

A14 16RD/WT FUSED B( + ) 8W-11-11
FUEL 30
A14 16RD/WT FUSED B(+) 8W-11-11
PUMP
RELAY 85 K31 20BR/WT FUEL PUMP RELAY CONTROL 8W-11-11
86 F18 2 0 L G / B K FUSED I G N I T I O N SWITCH OUTPUT (START/RUN) 8W-11-11
87 A61 16DG/BK FUEL PUMP RELAY OUTPUT 8W-11-11

30 A16 14GY/WT FUSED 3( + ) 8W-11-10
AUTOMATIC
SHUT DOWN
85 K51 2 2 D B / Y L AUTO SHUT DOWN RELAY CONTROL 8W-11-10
RELAY F18 2 0 L G / B K FUSED I G N I T I O N SWITCH OUTPUT (START/RUN) 8W-11-10
86
F18 2 0 L G / B K FUSED I G N I T I O N SWITCH OUTPUT (START/RUN) 8W-11-10
87 A142 14DG/0R AUTO SHUT DOWN RELAY SENSE 8W-11-10

30 F31 20VT FUSED B(+) 8W-11-8
85 C13 22DB/0R A / C COMPRESSOR CLUTCH RELAY CONTROL 8W-11-8
86 F18 2 0 L G / B K FUSED IGNITION SWITCH OUTPUT (START/RUN) 8W-11-8
87 C3 18DB/BK A / C COMPRESSOR CLUTCH RELAY OUTPUT 8W-11-8

30 F31 20VT FUSED B(+) 8W-11-7
85 X3 22BK/RD HORN RELAY CONTROL 8W-11-7
86 F31 20VT FUSED B(+) 8W-11-7
X2 18DG/RD HORN RELAY OUTPUT 8W-11-7
87
X2 18DG/RD HORN RELAY OUTPUT 8W-11-7
TRAILER 30 A6 12RD/TN FUSED B(+) 8W-11-6

TOW 85 11 20BK GROUND 8W-11-6
RELAY 86 L7 2 0 B K / Y L PARK LAMP SWITCH OUTPUT 8W-11-6
87 L76 1 2 B K / 0 R T R A I L E R TOW RELAY OUTPUT 8W-11-6
8040bffa J968W-9
BR 8W-11 POWER DISTRIBUTION 8W -11 - 5

TRANSMISSION 30 A14 16RD/WT FUSED B(+) 8W-11-9
RELAY 85 K30 20PK TRANSMISSION RELAY CONTROL 8W-11-9
86 F18 20LG/BK FUSED IGNITION SWITCH OUTPUT (START/RUN) 8W-11-9
87 T16 18RD TRANSMISSION CONTROL RELAY OUTPUT 8W-11-9

30 L7 20BK/YL PARK LAMP SWITCH OUTPUT 8W-11-13.14
85 Z l 18BK GROUND 8W-11-13.14
G34 18RD/GY* HIGH BEAM INDICATOR LAMP DRIVER 8W-11-13.14
86
L3 16RD/0R** DIMMER SWITCH HIGH BEAM OUTPUT 8W-11-13.14
A87 L139 20LB/WT FOG LAMP RELAY OUTPUT 8W-11-13.14

FOG 30 L39 20LB FRONT FOG LAMP SWITCH OUTPUT 8W-11-12
LAMP 85 L35 22BR/WT FOG LAMP RELAY CONTROL 8W-11-12
RELAY
NO. 2 86 L139 20LB/WT FOG LAMP RELAY OUTPUT 8W-11-12
87 L38 20LB/BK FUSED B ( + ) 8W-11-12
* WITH DRL
** WITHOUT DRL
8040bffb J968W-9
8W-11 - 6 8W-11 P O W E i DISTRIBUTION BR
B A T T E R Y
P O S I T I V E
T E R M I N A L
C8W-20-3 4) P
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH D I E S E L ENG)
( 8 W - 2 0 - 4 )
E N G I N E S P L I C E
STARTER S 1 4 8
MOTOR ( 8 W - 7 0 - 2 1 )
iW-21~3 4) p E L E C T R I C
B R A K E
P R O V I S I O N
J O I N T (BOTTOM
CONNECTOR LEFT OF
PARK I.P.)
LAMP
SWITCH
OUTPUT
(4) C 2 1 7
17
18BK
YL
POWER
C 1 3 3 (86) D I S T R I B U T I O N
C E N T E R
TRAILER
17 L7 TOW A6
18BK 20BK RELAY 12RD
YL YL TN
(85) (87) ^ C1SO

S 1 0 6
•L76 12BK/0R-
8W-70-4
11
20BK
"1 L76
C 1 2 9 o >
A6
12RD
C 1 2 9
12BK TN
$108 OR
8W-70-5
Zl
+ C 3 3 2
+ C332
I2BK L76 A6
12BK 12RD
OR TN
nil
8W-15-3
• •
TRAILER TRAILER
TOW TOW
(8W-54-4) (8W-54-4)
* WITH GAS ENG
** WITH DIESEL ENG
8040bffc J968W-9
BR 8W-11 POWER DISTRIBUTION 8W-11-7
BATTERY
POSITIVE
TERMINAL
(8W-20-3,4)
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH DIESEL ENGINE SPLICE
ENG) STARTER S148
(8W-20-4) MOTOR (8W-70-21)
(8W-21-3,4)
LOW NOTE HORN

(8W-41-4)
X3 POWER WINDOWS
22BK AND POWER LOCKS
RD
VEHICLE SPEED
CONTROL/HORN
SWITCH
C8W-41-4)
* WITH GAS ENG

* * WITH DIESEL ENG
8040bffe J968W-9
8W-11 -8 8W-11 POWER DISTRIBUTION BR
BATTERY
POSITIVE
TERMINAL
<8W-20-3,4)
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH
DIESEL ENG)
C8W-20-4) ENGINE
STARTER SPLICE
MOTOR S148
C8W-21-3.4) (8W-70-21)
POWER
DISTRIBUTION
CENTER
A/C
COMPRESSOR
CLUTCH
C8W-42-8) * WITH GAS ENG
** WITH DIESEL ENG
8040cc00 J968W-9
BR 8W-11 POWER DISTRIBUTION 8W-11 - 9
BATTERY
POSITIVE
TERMINAL
<8W-2©-3,4)
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH
DIESEL ENG)
(8W-20-4)
* WITH GAS ENG

** WITH DIESEL ENG
8040cc01 J968W-9
8W-11 -18 — 8W-11 POWER DISTRIBUTION BR
POWER
BATTERY DISTRIBUTION
POSITIVE FUSE 4 Mil CENTER
TERMINAL
(8W-20-3.4)
A l 12RD —i
C133
Al
AO 12RD
RIGHT 14PK** S124
Al
BATTERY 8W-70-12
POSITIVE
TERMINAL
(WITH
ENGINE
STARTER
SPLICE
S148
•
P
FUSE BLOCK.
2RD"
Al
12RD
DIESEL ENG) MOTOR (8W-70-21) (8W-10-5)
(8W-20-4) <8W-21-3,4) 1 C212
r•
mm IGNITION
SWITCH
START \ ACC
C212 !
•F18 22LG/BK A 2 1 12DB"~ <ff
RUN OFF
(2)J
C133
F18
20LG
BK
1
#—F18 20LG/BK-1 - A 1 6 14GY/WT-
S114
8W-70-7
WITH
POWER DIESEL
(8^^(30)""
cieo AUTOMATIC
DISTRIBUTION
CENTER A142
ENG
F18 A142 A142
20LG SHUT DOWN 14DG 14DG 14DG
BK RELAY OR OR OR
S138 S143
8W-70-17 8W-70-19
(85) (87) C180
K51 A142 A142

22DB 16DG 16DG
YL OR OR
TRANSMISSION C127
RELAY
• A 1 4 2 14DG/0R {{
(8W-11-9)
(8W-31-4)
C125
•K51 20DB/YL-
A142
16DG
OR
C137
POWERTRAIN
CONTROL
MODULE
* WITH GAS ENG

* * WITH DIESEL ENG
8040cc02 J968W-9
BR 8WH POWER DISTRIBUTION 8W-11 -11
POWER
POSITIVE FUSE 8 C180 CENTER
TERMINAL AO 6 R D — G © Q U r
(8W-20-3,4)
RIGHT AO
BATTERY QOERD**
POSITIVE
TERMINAL
(WITH DIESEL ENG)
(8W-20-4) (8W-70-21)STARTER
7 0 Z 1 }
E M G I N E
AUTOMATIC MOTOR
SHUT DOWN (8W-21-3,4)
RELAY
(8W-11-10)
(8W-30-12) F18
22LG
BK
F18 F18
+ C133
20LG 20LG F18
BK BK 20LG A14
BK $114 16RD
TRANSMISSION WT
8W-70-7 RELAY
-F18 20LG/BK- C8W-11-9)
(8H-31-4)
TRANSMISSION F18
RELAY 18LG
BK
(8W-11-9)
(8W-31-4) ^ C126
F18
18LG
BK S132
POWER
8W-70-13 DISTRIBUTION
CENTER
F18 F18
20LG 20LG
BK BK
(2) : C153 (2) C146
DUTY F18 EXHAUST
CYCLE 20LG GAS
BK* FUEL
EVAP/ RECIRCULATION
PURGE I SOLENOID K31
20BR
A61
16DG
PUMP
MODULE
SOLENOID F18 (WITH 5.2L
18LG WT BK (8W-30-21,42)
(WITH AND 5.9L NOT
BK** USED
GAS ENG) ENG) C127 C129
(1) : C153 (1)
V C146 ON
K31
K35 DIESEL
K52 20BR -A61 16DG/BK- 1
20PK 20GY WT
YL
AC20
C137
A2
C135
B32
.± C136 ^ - C137
C19
C137
A22
cC13S
r
POWERTRAIN
EGR FUEL FUSED
CONTROL
EVAP FUSED MODULE
SOL IGN SW SOL PUMP B(+)
CONTROL OUTPUT CONTROL RLY
(START/RUN) CONTROL
WITH GAS ENG
WITH DIESEL ENG
8040cc03 J968W-9
8W-11 POWER DISTRIBUTION BR
BATTERY
POSITIVE
TERMINAL
(SW-20-3,4)
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH DIESEL ENGINE SPLICE
ENG) STARTER' S148
(8W-20-4) MOTOR (8W-70-21)
(8W-21-3,4)
FOG LAMP
RELAY NO. 1
(8W-11-13,X4)
(8W-50-8)
RIGHT
FOG LAMP
(8W-S0-10)
LEFT
FOG LAMP
C8W-50-10)
FOG
LAMP
SWITCH
(8W-50-10)
* WITH GAS ENG

** WITH DIESEL ENG
8040cc04 J968W-9
BR 8W-11 POWER DISTRIBUTION 8W-11 - 1 3
POWER
BATTERY C180 DISTRIBUTION
POSITIVE CENTER
TERMINAL I
(1) A7
<8W-20-3,4) 10RD
B K
, S147
AO
OERD 8W-70-21
RIGHT
BATTERY
POSITIVE
A7
TERMINAL ^ 12RD
(WITH DIESEL BK
ENG) ENGINE SPLICE
(8W-20-4) STARTER S148 ^ C133
MOTOR (8W 7 0 - 2 1 )
A7
C8W-21-3 4 ) 12RD
12RD/BK
BK
S204
l
A7
12RD-
BK DAYTIME
WITH RUNNING
POWER LAMP
SEAT " MODULE
CAVITY 4
(8W-50-12)
(8W-11-14)
(8W-11-14)
(8W-70-10)
8W-70-23
L3 G34
16RD 18RD
OR GY
WITH
DRL
POWER
DISTRIBUTION
FOG CENTER
LAMP
RELAY
PARK PARK JOINT

CONNECTOR S103
LAMP LAMP
SWITCH SWITCH A 8W-70-3
OUTPUT OUTPUT FOG LAMP
RELAY NO. 2
C8W-11-12) Zl
C8W-50-9) 18BK
G102
8W-15-4
* WITH GAS ENG

* * WITH DIESEL ENG
8040cc05 J968W-9
8W-11 -14 8W-11 POWER D I S T R I B U T E BR
POWER
BATTERY FUSE 6 £19-°- DISTRIBUTION
POSITIVE CENTER
TERMINAL
(8W-20-3,4)
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH DIESEL
ENGINE SPLICE
ENG)
STARTER. S148
(811-20-4)
MOTOR (81-70-21)
(8W-21-3,4)
DAYTIME RUNNING
LAMP MODULE
HIGH FUSED
C131 BEAM
WITH 4 INDICATOR
DRL LAMP
DRIVER DIMMER
G34
SWITCH i
18RD
HIGH BEAM
GY
OUTPUT
S153
8W-70-23 WITHOUT
DRL
SPLICE G34
S106 18RD L3 16RD/0R
(8W-11-13) GY
(8W-70-4)
L7
20BK
YL
(30) (86) C180
DIMMER
NO. 1 SWITCH
HIGH BEAM SWITCH
(A87) (85) CIS© OUTPUT (PART OF A3
MULTI 12RD
HEADLAMP
FUNCTION LG
SWITCH FUSED
SWITCH)
L139 OUTPUT B( + )
Zl
20LB
18BK
WT
S103
8W-70-3
FOG LAMP
RELAY NO. 2
(8W-11-12) Zl
(8W-50-9) 18BK
G102
• 8W-15-4
WITH GAS ENG

WITH DIESEL ENG
8040cc06 J968W-9
BR- 8W-11 POWER DISTRIBUTION 8W-11 - 1 5
BATTERY
POSITIVE
TERMINAL
(8W-20-3,4)
AO AO AO
OERD 6RD* 20BK*
AO AO
RIGHT OOERD** 14PK**
BATTERY
POSITIVE i POWER
TERMINAL DISTRIBUTION
(WITH DIESEL ENG) CENTER
(8W-20-4)
ENGINE SPLICE
STARTER S148
MOTOR <8W 7 0 - 2 1 )
(8W-21-3.4)
IGNITION
SWITCH
C212
-» A2 12PK/BK
(4)
START
CONTROLLER
* ABS
ANTI-LOCK.
r
FUSED I G N I T I O N
WARNING
SWITCH OUTPUT BRAKE
(RUN)
LAMP
(ABS)
RELAY
::
f
(8W-11-16)
12 17 21 (8W-35-6)
A20
18RD
C121
T--T- '¥ DB
ABS
A20
18RD
DB
A20
18RD
DB
A20
18RD
DB
A20
18RD
DB
A20
-A20 18RD/DB- L PUMP
MOTOR
RELAY
(8W-11-16)
(8W-35-6)
WITH
RWAL
A20 18RD/DB A20 18RD/DB- VACUUM

SENSOR
S110 (WITH
C133 8W-70-6 DIESEL ENG)
-A20 18RD/DB -A20 18RD/DB- (8W-34-4)
C8W-35-5)
3
CONTROLLER
ANTI-LOCK WITH
FUSED
BRAKE RWAL
IGNITION
SWITCH (RWAL)
OUTPUT * WITH GAS ENG
(RUN) * * WITH DIESEL ENG
8040cc08 J968W-9
8W-11 -16 BR
BATTERY SPLICE
POSITIVE S148
•AO 2 0 B K * - -AO 14PK**
TERMINAL C8W-70-21)
<8W-20-3,4)
ENGINE
STARTER
MOTOR
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH D I E S E L
ENG)
C8W-20-4)
G19
20LG
RD
S158 S108
8W-70-25 8W-70-5
-B120 12BR/WT S112

Zl HYDRAULIC 8W-70-7
12BK CONTROL
G19 -B120 12BR/WT-
UNIT
20LG G1Q1
C8M-35-9)
RD 8W-15-3 -B120 12BR/WT- B120
14BR
^ C133 WT
B120
G19 12BR
22LG -G19 20LG/RD WT C121
RD
C121 34 CONTROLLER
4
ABS ABS ANTI-LOCK
( 1 4 ) ^ C21S » 24 13 !
CONTROLLER
ANTI-LOCK PUMP PUMP BRAKE
ABS INSTRUMENT J ABS ABS »
MOTOR MOTOR
WARNING CLUSTER i WARNING WARNING ! BRAKE
RWAL RELAY RELAY
LAMP | LAMP LAMP i OUTPUT CONTROL
DRIVER i DRIVER RELAY J VALVE
CONTROL « (8W-35-10) J
* WITH GAS ENG
* * WITH DIESEL ENG
8040cc09
J968W-9
BR —- 8W-11 POWER DISTRIBUTION — — — — oi»
BATTERY SPLICE
POSITIVE -AO 20BK* S148
AO 1 4 P K * * -
TERMINAL C8M-70-21)
(8W-20-3„4)
ENGINE
STARTER MOTOR
(8W-21-3,4)
FUEL SHUT
RIGHT T40 12BR — { ( — - T 4 0 12BR- m RELAY
BATTERY C8W-30-47)
POSITIVE
TERMINAL C119
(WITH
D I E S E L ENG) T40 12BR »—T40 12BR-
(8W-20-4)
t
ENGINE
STARTER
MOTOR
POWER (8W-21-3.4)
DISTRIBUTION
CENTER
WITH
GAS ENG WITH
WITH
WITH ^DIESEL
AUTO
MAN ENG
Z12 T41 TRANS Z12
TRANS 20BK WITH MAN
20BK 20BK TRANS
TN WT TN
•I $151
8W-70-22 • S141
8W-70-I9 •1 S152
8W-70-22
Z12 T41 Z12

10BK 18BK 14BK
TN
FUSE
BLOCK S142
(8W-10-5)
3W-70-19
Z12
14BK
TN
G119
8W-15-12
Clif
PARK/ "
NEUTRAL
POSITION
SWITCH
CASE
•=• GROUND
• A41 18DB/YL * WITH GAS ENG

** WITH D I E S E L E
8040cc0a J968W
BATTERY ENGINE
POSITIVE STARTER
TERMINAL •AO 6RD* AO OOERD**-
MOTOR
CSW-20-3,4) <8W-21-3,4)
RIGHT
BATTERY
POSITIVE
TERMINAL
(8W-20-4)
HAZARD
WARNING
FLASHER
8W-52-3)
WITH
I - POWER
A7 A7 SEAT
12RD 12RD
BK BK
S204 12BK
OR
S201
•A7 1 2 R D / B K - 8W-70-28 8W-70-26
A7 A7 A22 A22 A22

12RD 12RD 12BK 12BK 12BK
BK BK OR OR OR
FUSE 1 FUSE
(14)'
. _
^ C241 I BLOCK (7) (11) (23) C24I BLOCK
! ) FUSE J ) FUSE ) FUSE \ CB2 1 \ CB1 S F2 SS FUSE S FUSE J FUSE

17 C 18 C 19 ) 30A ! J 30A C 30A C 14 C 15 C 16
i > 15A * 15A < > 20A < 20A * 10A * 15A
* WITH GAS ENG

40cccl J968W-9
8W-11 POWER DiSTRiiUTiOi J W - 1 1 -19
BATTERY ENGINE
POSITIVE STARTER
TERMINAL •AO 6RD* AO OQERD* MOTOR
(8W-20-3.4) (8W-21-3,4>
SPLICE
S148
(8W-70-21)
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH DIESEL ENG)
(8W-20-4)
FUSE BLOCK
(8W-10-5)
GENERATOR
(8W-20 3.4)
FUSE
BLOCK
* WITH GAS ENG

* * WITH DIESEL ENG
8040ccc2 J968W-9
8W-11 -20 8W-11 POWER DISTRIBUTION
POSITIVE
TERMINAL
(8W-26-3,4)
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH DIESEL ENG)
(8W-20-4) FUSE
BLOCK
(81-10-5)
F U E L PUMP
RELAY
(8W-11-11)
(81-30-20,41)
A / C COMPRESSOR
TRANSMISSION
CLUTCH RELAY
RELAY
(8W-11-8)
(8W-11-9)
(8W-31-4)
(81-42-8)
F U E L SHUT
DOWN S O L E N O I D
(8W-30-47)
HEATED INTAKE
A I R SYSTEM
R E L A Y NO. 1
(8W-30-48)
POWERTRAIN iiTY EXHAUST FUEL HEATED

CONTROL CYCLE GAS HEATER INTAKE
MODULE EVAP/ RECIRCULATION RELAY A I R SYSTEM
CAVITY A2 PURGE SOLENOID (8W-30-47) R E L A Y NO. 2
(8W-30-20.41) SOLENOID (8W-30-20) (8W-30-48) * WITH GAS ENG
(8W-3Q-20)
** WITH DIESEL ENG
8040ccc3 J968W-9
8W-11 POWER DISTRIBUTION 8W-11 -21
(WITH GAS ENG)
AUTOMATIC C127
S H U T DOWN
RELAY
(81-11-10)
(81-30-12)
INJECTOR
NO. 1 0
(81-30-40)
POST
CATALYST
HEATED
OXYGEN
SENSOR
(81-30-38)
UPSTREAM
HEATED
OXYGEN
SENSOR
(81-30-29
32,33)
INJECTOR
810.2
WITH 3 . 9 L . 5 . 2 L (81-30-31,
AND 5 . 9 L ENG 35,40)
DOWNSTREAM
HEATED INJECTOR
OXYGEN NO.4
SENSOR (81-30-31.
(81-30-29, 35,40)
32,33)
LEFT
UPSTREAM
HEATED
INJECTOR
OXYGEN
10. §
SENSOR
(81-30-31,
(81-30-37)
35,40)
INJECTOR
WITH 8 . 0 L ENG NO.8
(81-30-
RIGHT 35,40)
UPSTREAM
HEATED
OXYGEN 2L.5.9L
SENSOR AND 8 . 0 L ENG
(81-30-37)
INJECTOR GENERATOR
NO.l (81-20-3)
(81-30-30,
34,39)
8040ccc4 J968W-9
(WITH DIESEL ENG)
AUTOMATIC
S H U T DOWN C127
RELAY • A142 14DG/0R-
C8M-1I-10)
(8W-30-12)
A142
14DG
OR
EXHAUST
OAS S143
RECIRCULATION • A142 18DG/0R
SOLENOID
(8W-30-49)
WITH
EGR
EGR
CONTROL
GENERATOR
MODULE • A142 20DG/0R A142 14DB- C8W-20-4)
CAVITY 1
A142
(8W-30-49)
16DG
OR
C137
POWERTRAIN
CONTROL
MODULE
8040ccc5 J968W-9
BR 8W - 12 JOINT CONNECTORS 8W - 12 -1
8W-12 JOINT CONNECTORS
DESCRIPTION AND OPERATION WIRING DIAGRAM INDEX

The following index covers all components found in
INTORDUCTION this section of the wiring diagrams. I f the component
This section identifies the internal circuity of the you are looking for is not found here, refer to section
joint connectors. For additional information on sys 8W-02 for a complete list of all components shown in
tem operation, refer to the appropriate section of the the wiring diagrams.
wiring diagrams.
8W-12-2 8W-12 JOINT CONNECTORS BR
DIAGRAM INDEX
Controller Anti-Lock Brake 8W-12-5, 7, 8,10 Fuse 20 8W-12-5
Daytime Running Lamp Module 8W-12-7 Headlamp Switch . , . 8W-12-3,4, 6, 8
Fusel (PDC) 8W-12-3.6 Ignition Switch 8W-12-7,9,10
Fuse 2 (PDC) 8W-12-9 Instrument Cluster 8W-12-6, 7,10
Fuse 3 (PDC) 8W-12-7 Joint Connector A 8W-12-3,4,6
Fuse 6 (PDC) 8W-12-5 Joint Connector B 8W-12-5
Fuse 11 8W-12-7 Joint Connector C 8W-12-3, 6, 7, 8, 9,10
Fuse 13 8W-12-3.6 Overhead Console 8W-12-3, 4, 6, 7
Fuse 15 8W-12-9 Park Brake Switch 8W-12-7
Fuse 17 8W-12-5 Powertrain Control Module 8W-12-6, 8
Fuse 18 8W-12-3.6
8040ccc6 J968W-9
BR- 8W-12 JOINT CONNECTORS 8W-12-3
BATTERY RIGHT BATTERY
POSITIVE POSITIVE TERMINAL
TERMINAL (WITH DIESEL ENG)
(8W-20-3.4) C8W-20-4) C133
•A7 1 2 R D / B K - » - A 7 12RD/BK •
POWER
AO 6RD- DISTRIBUTION
FUSE S147 CENTER
1
8W-70-21
BOA
AO AO (1)
OOERD** 14PK** C180
SPLICE •A7 10RD/BK-
S148
(8W-70-21)
ENGINE
STARTER
MOTOR WITH
E2 220R E2 200R
FOG
(8W-21-3,4) LAMPS
FOG LAMP REF TO
SWITCH OVERDRIVE
(8W-50-10) SWITCH
ILLUMINATION
LAMP
(8W-31-7)
SPLICE
S106 RADIO
(8W-70-4) (8W-47-4,6)
E2
200R L7
18BK
YL
L7
C133 20BK
YL
L7
18BK
YL
(5) C209 (4) (9):
FUSED
PANEL
LAMPS
DIMMER (10)
SWITCH
SIGNAL JOINT CONNECTOR A
(5): C217 WITH
JOINT OVERHEAD
CONNECTOR C CONSOLE ONLY
OVERHEAD
C338 PARK LAMP CONSOLE
C208
L7 2 0 B K / Y L -
—«- SWITCH
OUTPUT
1
J
(2) i J
L~ L7 20BK/YL—
SPLICE
L7 1 8 B K / Y L - S317
(8W-70-40)
WITH CLEARANCE
AND I . D . LAMPS * WITH GAS ENG
* * WITH DIESEL EN
8040ccc7 J968W-
OVERHEAD OVERHEAD LEFT DOOR RIGHT DOOR

CONSOLE NAP/COURTESY JAMB JAMB DOME
- LAMP SNITCH SWITCH LAMP NO
(8W-49-5) (8W-49-4) (8W-49-4) (8W-44-5) CONNECTION
COURTESY
LAMPS
DRIVER
| . ^ ciaa
M2 M2
( 6 ) >k C338 20YL 18YL
M2 M2 M2
+
M2
22YL 18YL 18YL ^ C202 C133
WITH 22YL
HIGH-LINE M2
CLUSTER 20YL M2
20YL
S218
C201 C240 8W-70-34
M2
22YL"~1
>js C208
M2 M2 M2 M2
22YL 22YL 22YL 20YL
(7): (8): (2) (6): C217

JOINT
CONNECTOR A
, _ J
(3): (1): C217
TIME'DELAY
-M2 2 2 Y L - RELAY
C8W-44-4»5)
HEADLAMP
SWITCH
DOME
M2 20YL-
8040ccc9 J968W-9
BR- 8W-12 JOINT CONNECTORS 8W-12-5
RIGHT
BATTERY '
BATTERY
POSITIVE
POSITIVE
AO OERD- TERMINAL
TERMINAL
(WITH
(8W-20-3,4)
DIESEL ENG) • HOT A T A L L T I M E S ^
(8W-20-4) JOINT *~» FUSE
CONNECTOR JB S205
BLOCK
C231 8W-70-28
FUSE
Ml Ml 17
AO
18PK 18PK" 15A
20BK*
(8)
(17); C241
AO AO
OOERD** 14PK**
DATA L I N K
ENGINE SPLICE
- M l 20PK CONNECTOR
STARTER S148
(7) (8W-30-13)
MOTOR (8W-70-21)
(8W-21-3,4)
RADIO
POWER •Ml 18PK- CHOKE
DISTRIBUTION (8W-47-7)
FUSE (6)
CENTER
6
40A
(6): C180
GLOVE BOX
-Ml 20PK- LAMP/
A3
(2) SWITCH
12RD
LG (8W-44-8)
f
WITH RADIO
I
A3 A3
DRL •Ml 20PK-
(8W-47-4,6,7)
12RD 12RD
(1)
LG LG
S118
A3
-12RD- 8W-70-9 STOP LAMP
LG •F32 18PK/DB- SWITCH
A3
12RD (5) (8W-51-8)
LG
X C133
A3 C231 CONTROLLER
C228
12RD ANTI-LOCK
LG )> F32 20PK/DB (f BRAKE
(4) (9) (RWAL)
S203
8W-70-27
A3 FUSE B L O C K
12RD
LG
C241 FUSE 20 £241
-F32 18PK/DB-
* WITH GAS ENG
(16) 15A (20) * * WITH DIESEL ENG
8040ccca J968W-9
8W-12-&- 8W-12 JOINT CONNECTORS mm
BATTERY RIGHT BATTERY
POSITIVE POSITIVE TERMINAL
TEMIltlAL (WITH D I E S E L ENG)
(8W-20-3 (8W-20-4) C133
A7 1 2 R D / B K - ) > - A 7 12RD/BK •
POWER j
AO 6RD- DISTRIBUTION I
1
CENTER
AO AO
6RD* 20BK*
] I
AO AO (1) C18Q
OOERD** 14PK** 1
-A7 10RD/BK —
| SPLICE
$148
ENGINE C8W-70-21)
STARTER
MOTOR WITH FOG E2 220R- E2 200R
C8W-21-3,4) LAMPS
E2
200R FOG LAMP OVERDRIVE
SWITCH SWITCH
(8W-50-10) ILLUMINATION
LAMP
(5) : C209 (8W-31-7)
JOIWT
C209 CONNECTOR
E2 220R- RADIO
CSW-47-4,6)
(l)i
! INSTRUMENT
I
CLUSTER
C21S FUSED PANEL
»E2 220R- <f-| LAMPS DIMMER
SWITCH SIGNAL
(2) (1)
HEATER A/C-HEATER
E2 CONTROL CONTROL
OR
/
/ T 220R SWITCH SWITCH
(3)| C8W-42-4) C8W-42-6)
OVERHEAD
C208 C338 ! FUSED PANEL CONSOLE
-»!~E2 220R—<f-E2 2 2 0 R — ( f - | LAMPS DIMMER (WITH
(4)i (1) i HIGH-LINE
J
CLUSTER) PARK
JOINT
LAMP CONNECTOR A
SWITCH
OUTPUT
-V32 20YL/RD-
STOP LAMP
SWITCH
(17)j
(8W-33-4)
VEHICLE
SPIES
-V32 22YL/RD- CSMTRGL/HORN
(19] SWITCH
C8M-33-3)
WITH GAS ENG

8040cccc J968W-9
BR 8W-12 JOINT CONNECTORS 8W-12-7
BATTERY
SPLICE
POSITIVE
AO 20BK* S148
TERMINAL AO 14PK** (8W-70-21)
(8W-20-3,4) ENGINE
•AO OOERD* STARTER
- AO 6RD*-
MOTOR
POWER (8W-21-3.4)
AO DISTRIBUTION
6RD CENTER
! § FUSE 3 ^ i i i -
IGNITION
40A ) Al ' ACC SWITCH
AO ( 3 S124 ! *
OERD 12RD
C133 8W-70-12 C212 OFF |
| — A l 12RD—<f
RIGHT
BATTERY (7)
'RUN j
POSITIVE
TERMINAL ! START
(WITH DIESEL
ENG)
C8W-20-4) FUSED OVERHEAD
C338 IGNITION CONSOLE
SWITCH (WITH
F12
-<f
(7)
OUTPUT HIGH-LINE
(START/RUN) CLUSTER)
OVERDRIVE BUZZER 22DB
SWITCH MODULE WT
C8W-31-7) (8W-44-7)
C208
F12 F12
22DB 20DB F12
WT WT 22DB
WT
(14) (13) (15)
(11) (10) ; (9)
Gil
22WT
BK
Gil Gil
C133 22WT 22WT
BK BK BLACK
Gil
20WT
BK
^ C131 (5): C216 C228

DAYTIME 1 INSTRUMENT CONTROLLER
3 PARK 5
PARK RUNNING BRAKE CLUSTER PARK ANTI-LOCK.
BRAKE LAMP SWITCH BRAKE BRAKE CASE
SWITCH MODULE SENSE SWITCH (RWAL) GROUND * WITH GAS ENG
SENSE SENSE ** WITH DIESEL ENG
8040ccce J968W-9
POWERTRAIN
CONTROL
MODULE
CONTROLLER
ANTI-LOCK
BRAKE
KEY-IN S W I T C H /
HALO LAMP
C8W-44-7)
LEFT POOR
J A M B SWITCH
(8W-49-4)
BiHER MODULE
C8W-44-7)
K E Y - I N SWITCH/
H A L O LAMP
C8W-44-7)
8040ccd0 J968W-9
BR- 8W-12 JOINT CONNECTORS 8W-12-9'
SPLICE
-AO 20BK* AO 1 4 P K * * - S148
(8W-70-21)
BATTERY ENGINE
POSITIVE STARTER
AO OOERD*
TERMINAL ' MOTOR
(8W-20-3,4) (8W-21-3.4)
POWER
C180 i DISTRIBUTION
CENTER
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH D I E S E L A2 12PK/BK — 1
ENG)
(8W-20-4)
WITH
HIGH-LINE
CLUSTER
DAY/
NIGHT
•L10 22BR/LG-
MIRROR
C208 (8W-44-9)
f
L10
22BR
LG
(30): C209 (28)
C209
(29)
L10
22BR
LG
C133
C126
•L10 18BR/LG- -<(— •L10 18BR/LG-
$120 L10
-18BR-
•L10 20BR/LG-
8W-70-10
|—L10
C126
1 8 B R / L G — — L10 18BR/LG-
LG
"1 1
1 WITH
WITH h»— MAN
L10 L10 L10 TRANS
DRL
18BR 18BR 18BR
LG LG LG
DAYTIME
RUNNING
LAMP i
MODULE PARK/NEUTRAL BACK-UP
CAVITY 5 POSITION LAMP
(8W-50-12) SWITCH SWITCH
(8W-51-6) C8W-51-6)
* WITH GAS ENG

* * WITH D I E S E L EN
8040ccd2 J968W-
8W-12-10 8W-12 JOINT CONNECTORS
CONTROLLER
ANTI-LOCK
RED
BRAKE
BRAKE
WARNING
(ABS)
LAMP DRIVER
25
C121
BRAKE
SWITCH
C8W-34-4)
(8W-35-5)
BLACK-
INSTRUMENT
CLUSTER
RED
BRAKE
WARNING
WITH LAMP DRIVER
ABS
(4): C216
WITH BRAKE
DIESEL SWITCH
ENG C8W-34-4)
CONTROLLER
RED
AiSTI-LOCK
BRAKE BRAKE
-BLACK (RWAL)
WARNING
LAMP DRIVER
6
VACUUM
G9 G9
SENSOR -C228
20GY 18GY
(8W-34-4)
BK BK
(8W-35-5)
WITH CASE
• RWAL GROUND
WITHOUT
DIESEL
IGNITION
SWITCH
C212
START \ ACC]
C133
G9 G9
22GY (3)
22GY RUN OFF i
BK BK
G9 G9
22GY 22GY
BK BK
(26) : (23) : (24): (25) : C209

JOINT
CONNECTOR
C
8040ccd4 J968W-9
BR 8W - 15 GROUND DISTRIBUTION 8W - 15 -1
8W-15 G R O U N D D I S T R I B U T I O N
INTRODUCTION
This section identifies the grounds, splices that
connect to those grounds, and the components that
connect those grounds. For additional information on
system operation, refer to the appropriate section of
the wiring diagrams. For an illustration of the phys
ical location of each ground, refer to group 8W-90.
8W • 15 - 2 8W-15 GROUND DISTRIBUTION — — BR
DIAGRAM INDEX
G101 8W-15-3 G114 8W-15-10
G102 8W-15-4 G115 8W-15-10
G103 8W-15-5 G116 8W-15-10
G104 8W-15-6, 7,8 G117 8W-15-10
G105 8W-15-6, 7,8 G118 8W-15-10
G106 8W-15-6, 7, 8 G119 8W-15-11,12
G107 8W-15-9 G201 8W-15-13
G108 8W-15-9 G202 8W-15-13
G109 8W-15-9 G301 8W-15-14
G110 8W-15-9 G302... 8W-15-14
G111 8W-15-9 G303 8W-15-15
G112.: 8W-15-10 G304 8W-15-15
G113 8W-15-10
8040ccd6 J968W-9
BR- 8W-15 GROUND DISTRIBUTION 8W-15-3
WITH ABS
TRAILER
TOM RELAY ABS WARNING
(8W-54-4) LAMP RELAY
(8W-11-6) (8W-35-6)
(8W-1I-16)
LOW
Z l 18BK-
WASHER FLUID
SWITCH
(8W-53-4)
11 20BK-
x
WITH
SPEED CONTROL,
H I G H - L I N E CLUSTER
VEHICLE SPEED
CONTROL SERVO
(8W-33-4) VACUUM
C131 SENSOR
! 8
9 ! (8W-34-4)
, GND GND J (8W-35-5)
j
DAYTIME RUNNING
LAMP MODULE Zl WITH
12BK DIESEL ENG
Zl
12BK
WITH
LOW-LINE
CLUSTER
SPLICE
HIGH Zl
S103
NOTE HORN 12BK (8W-15-4)
(8W-41-4) C8W-70-3)
WITH Zl
A 14BK
LOW HIGH-LINE- LEFT PARK/
NOTE HORN CLUSTER TURN SIGNAL
(I G1Q1 (8W-41-4) LAMP
C8W-52-6)
SPLICE (8W-50-5)
S115
<8W-15~6,7,8>
(8W-70-8)
* WITH MEDIUM-LINE AND H I G H - L I N E CLUSTER

8040ccd8 J968W-9
8W-15-4 8W-151SR0UND DISTRIBUTION BR
4MD
SWITCH
(8W-31-8) LEFT PARK/
RIGHT FOG LAMP C8W-34-6) TURN S I G N A L
FOG LAMP RELAY N O . l C8W-35-7) LAMP
(8W-50-10) (8W-50-8) (8W-40-9) (8W-52-6)
(8W-11-13,14) C8W-50-5)
Zl 18BK-
Zl
20BK
RIGHT P A R K /
S409 TURN S I G N A L
8W-70-43 •Zl 20BK Z l 18BK- LAMP
(8W-52-6)
csw-si-si
RIGHT
Zl Zl 20BK- HEADLAMP
20BK
(8W-50-5)
LEFT
FOG LAMP
(8W-50-10)
WINDSHIELD
WASHER
PUMP MOTOR
C8W-53-4)
8040ccda J968W-9
BR 8W-15 GROUND DISTRIBUTION 8W-15-5
LEFT D O O R R I G H T DOOR
PREMIUM PREMIUM
SPEAKER SPEAKER
(8W-47-8) (8W-47-9)
WITH
RWAL
RNAL
WALWE -Z8 16BK/PK
(8W-34-7)
CONTROLLER
ANTI-LOCK
BRAKE i •Z7 18BK/RD
C A W I T Y 20
(8W-35-4)
WITH
ABS
WITH
ABS
RADIO S122**
CHOKE •Z2 18BK/LG Z2 18BK/LG 8W-70-11
(8W-47-7)
•Z2 18BK/LG•
•Z2 18BK/LG
•Z2
'
12
18BK 1
J
1 8 B K / L G —fP
LG
•Z2 18BK/LG
Z2
C202 18BK
LG WITH
STANDARD
SPEAKERS
Z2
18BK
LG
S301
8W-70-34
Z2 Z2 RADIO
18BK 18BK
<8W-47-5,7.8.9)
LG LG
•Z8 10BK/PK WITH
RWAL
LEFT REAR RIGHT REAR
ABS 2-WAY WITH
PREMIUM PREMIUM ABS
POWER FEED
SPEAKER SPEAKER
C8W-35-9) * WITH PREMIUM SPEAKERS
(8W-47-7) C8W-47-7)
** WITH MEDIUM-LINE AND H I G H - L I N E CLUSTER
8040ccdc J968W-9
8W-15-6 8W-15 GROUND DISTRIBUTION BR
SPLICE
S40S
TRAILER
Z13
Z13
18BK-
18BK-
LEFT
LICENSE
F
WITH
C8W-15-8)
C8W-70-42)
TOW LAMP DUAL REAR

(8W-54-4) C8W-51-4) WHEELS
SPLICE
, S401
Z13 18BK- (8W-15-7)
SPLICE
(8W-70-41)
_ S402
Z13 18BK- (8W-15-7)
(8W-70-41)
S311
Z13 12BK-
8W-70-37 FUEL
_^ PUMP
-Z13 16BK-
MODULE
Z13 16BK- (8W-30-21,42)
WINDSHIELD WITH
WIPER TRAILER
Z13 MOTOR Z13 Z13 TOW
18BK UNDERHOOD
(8W-53-4) 12BK 16BK
LAMP
t
BLACK
C342 (8W-44-8) C128 C128
Z13 Z13
18BK Z13
12BK
RIGHT
I
LICENSE
LAMP
(8W-51-4,10)
NO
CONNECTION
LEFT
WITH
HEADLAMP
HIGH-
(8W-50-5) LINE
CLUSTER
Zl Zl
18BK 20BK
GROUND
G104 JOINT
8040ccde (CONTINUED ON 8W-15-6,8) J968W-9

S401 LEFT T A I L ,
LEFT 8W-70-41 STOP A N D
BACK-UP TURN SIGNAL
-Z13 18BK Z13 18BK-
LAMP LAMP
(8W-51-7) (8W-51-5)
(8W-52-6)
WITH
TRAILER
TOW
$311
^•Z13 12BK-^1
8W-70-37
Z13 18BK-
ZL3 16BK
I WITH
T_ DUAL
REAR
Z13 Z13 WHEELS
18BK 18BK
WITH C343 C341

TRAILER
Z13 Z13 TOW Z13 Z13
12BK
Z13
€128:
16BK
Z13
C128
RIGHT
LICENSE
i i
18BK
LEFT
LICENSE
18BK
SPLICE
S405
16BK 12BK LAMP LAMP C8W-15-8)
(8W-51-4,10) (8W-51-4) (8W-70-42)
L
RIGHT RIGHT TAIL.
BACK-UP STOP A N D
LAMP TURN SIGNAL
(8W-51-7) LAMP
(8W-51-5)
(8W-52-6)
S115
8W-70-8
8 WITH
LEFT
HEADLAMP
Zl
t t*
Zl
HIGH-LINE
CLUSTER
(8W-50-5)
14BK 12BK
Zl Zl
T
Zl
V. Zl
WITH
DIESEL
ENG Zl 1 i
18BK 20BK 14BK 12BK 16BK
• G104
m mm • G106
8040ccel ( C O N T I N U E D ON 8M-1S-6.8) J968W-9

8W-15-8- 8W-15 GROUND DISTRIBUTION BR
C342 RIGHT
WITH LICENSE
-Z13 18BK- -Z13 18BK
T R A I L E R TOW LAMP
(8W-51-4,10)
$311 -Z13 12BK-

S312
8W-7Q-37 8W-70-38
-Z13 18BK-
-Z13 16BK-
LEFT
LICENSE C343
-Z13 18BK-
LAMP
(8W-51-4) -Z13 18BK-
WITH DUAL -Z13 18BK-

REAR WHEELS
S405
C408 8W-70-42
- « —
WITH
TRAILER Z13
' TOW 18BK
Z13 Z13 Z13
18BK 18BK 18BK
Z13 Z13 Z13
S408
12BK 16BK 18BK
8W-70-42 C405 Z13 C402 C403
^ C128 I>|. C 1 2 8 C4Q4 18BK
Z13 Z13 Z13 Z13 Z13

16BK 12BK Z13 Z13 Z13 18BK 18BK 18BK
18BK 18BK 18BK
RIGHT LEFT LEFT RIGHT LEFT LEFT RIGHT

TAILGATE TAILGATE REAR REAR LICENSE FORWARD FORWARD
LAMP LAMP FENDER FENDER LAMP FENDER FENDER
C8W-51-11) (8W-51-11) LAMP LAMP (8W-51-10) LAMP LAMP
(8W-51-12) CI W - 5 1 - 1 2 3 (8W-51-12) (8W-51-12)
$115
t
8W-70-8
WITH
WITH HIGH-LINE
LEFT f ' DIESEL CLUSTER
HEADLAMP ENG
(8W-50-S)
Zl
16BK
G105 G106
8040cce3 (CONTINUED ON 8W-15-6.7) J968W-9

mm 8W-15 GftOUNi DiSTRiBUTiOi 8W-15-9
SPLICE
$122
(8W-15-5)
(8W-70-11)
C133 €232 ! AIRBAG

CONTROL
-16 18BK/0R-
—
•16 1 8 B K / 0 R - «-\ 11 GND i
MODULE
• mm
-ZO 10BK-
BATTERY
NEGATIVE
•ZO 6BK-
TERMINAL
(WITH GAS ENG)
(8W-20-3)
ZO
8BK
• iioi • GllO I I 1G i l l
8040cce5 J968W-9
8W-15-10 8W-15 GROUND DISTRIBUTION BR
F U E L S H U T DOWN
-Z12 10BK/TN- SOLENOID
(8W-30-47)
G112
t WITH
DIESEL
ENG
Z l 6BK- GENERATOR
C8W-20-3.4)
G113
LEFT
BATTERY
NEGATIVE
TERMINAL
(WITH
D I E S E L ENG)
(8M-20-4)
RIGHT BATTERY
NEGATIVE
TERMINAL
(WITH
D I E S E L ENG)
(8W-20-4)
1118
8040cce7 J968W-9
RIGHT
DOWNSTREAM
POST PRE- LEFT UPSTREAM
HEATED
FUEL CATALYST CATALYST UPSTREAM HEATED
OXYGEN
PUMP HEATED HEATED ^ HEATED OXYGEN
SENSOR
MODULE OXYGEN OXYGEN OXYGEN SENSOR
(8W-30-29,32.33)
(8W-30-21) SENSOR SENSOR SENSOR (8W-30-37)
SPLICE (81-30-38) (8W-30-38) (8W-30-37)
UPSTREAM
5208 f f f
Zll HEATED
(8W-15-13)
(8W-70-30) 20BK
WT
I
Zll
I
Zll
1 •
Zll
OXYGEN
SENSOR
18BK 18BK 18BK
WT WT WT
^ C128
Zll
PARK/NEUTRAL
POSITION .
SWITCH
(8W-21-3)
BLACK
ENGINE
COOLANT
SENDING
UNIT
(8W-40-6)
A/C
ENGINE COMPRESSOR
STARTER CLUTCH
MOTOR (8W-42-8)
RELAY
(8W-21-3)
(81-11-17)
1119 (WITH GAS ENG)
WITH AUTO TRANS
8040cce9 J968W-9
8W-15-12 SW-11 GROUND DISTiiiUTiOi
EGR FUEL FUEL FUELSPLICE

' CONTROL SHUT DOWN HEATER PUMP S208
NODULE RELAY 'RELAY (8H-15-13)
NODULE
CAVITY 10 (8W-30-47) (8W-30-47) (8W-30-42) (8W-70-30)
(8W-30-49)
Z12 111 Zll

20BK 20BK 18BK
TN WT WT
X.
V
in
f
Zll
20BK
18BK
WT
WT
A/C
COMPRESSOR
CLUTCH
(8W-42-8)
G119 (WITH D I E S E L ENG)

FUEL
HEATER
(8W-30-47) * WITH AUTO TRANS
8040ccee J968W-9
FOG LAMP INTERMITTENT INSTRUMENT

SWITCH WIPER CONTROL CLUSTER
(8W-50-10) MODULE
GND j
(10) ^ C216
•Z3 20BK/0R Z3 2 0 B K / 0 R
WITH K EY - IN - SWITCH/
FOG Z3 2 0 B K / 0 R • HALO LAMP
LAMPS
C8W-44-5)
•Z3 20BK/0R Z3 2 0 B K / 0 R
HEADLAMP
SWITCH
(8W-44-5)
C8W-49-4)
Z3 16BK/0R
WITH
RWAL
CIGAR LIGHTER
BLACK OVERHEAD
POWER (8W-41-3)
OUTLET CONSOLE
(8W-41-3) GLOVE BOX
Z3 1 6 B K / 0 R - LAMP/SWITCH
(8W-44-8)
WITH
FOG
LAMPS
Z3 2 0 B K / 0 R -
FOG LAMP SWITCH
(8W-50-10)
INSTRUMENT C208
CLUSTER
WITH
OVERHEAD
CONSOLE
( 9 ) ^ C215 ( 6 ) ^ C216 •Zll 20BK/WT-
HEATER
CONTROL Zll Zll
SWITCH 20BK 20BK
(8W-42-4) WT WT
OR
A/C-HEATER —Zll 18BK/WT
CONTROL STOP S208 C133
SWITCH OVERDRIVE LAMP 8W-70-30 Zll
C8W-42-6) SWITCH SWITCH Zll 20BK/WT- 18BK
ILLUMINATION (8W-33-4) Zll WT
LAMP (8W-34-5) 18BK
(8W-31-7) (8W-35-7) WT
SPLICE
G202 S116
(8W-15-11,12)
(8W-70-8)
8040ccf0 J968W-9
8W-15-14 SW-15 GROUND DISTRIBUTiOi BR
CENTER HIGH MOUNTED

Z3 18BK/0R- STOP LAMP NO. 1
(8W-51-9)
•Z3 18BK/0R
CENTER HIGH MOUNTED
Z3 18BK/0R- STOP LAMP NO. 2
(8W-51-9)
S E A T BELT C303 POWER SEAT

SWITCH •Z3 18BK/0R Z3 14BK/0R- ({ Z3 14BK/0R- SWITCH
(8W-44-7) (8W-63-3)
WITH POWER
SEAT LEFT
POWER
Z3 14BK/0R- WINDOW
SWITCH
(8W-60-3)
•Z3 14BK/0R
LEFT POWER
DOOR
Z3 18BK/0R-
LOCK POWER
SWITCH MIRROR
C8W-61-3) •Z3 14BK/0R SWITCH
(8W-62-3)
Z3 18BK/0R-
L E F T DOOR
JAMB SWITCH -Z3 20BK/0R WITHOUT
(8W-49-4) POWER WINDOWS
AND POWER LOCKS
G302 (WIHOUT OPTIONAL)

LEFT
POWER
•Z3 14BK/0R- WINDOW
SWITCH
(8W-60-3)
•Z3 14BK/0R- S306*
L E F T POWER
POOR
8W-70-36
•Z3 18BK/0R-
LOCK POWER
SWITCH MIRROR
(8W-61-3) •Z3 14BK/0R- SWITCH
Z3 (8W-62-3)
14BK •Z3 18BK/0R-
OR
WITHOUT
POWER WINDOWS
C347 C347 AND POWER LOCKS
Z3 Z3
14BK 18BK
OR OR
L E F T DOOR
JAMB SWITCH Z3 18BK/0R-
(8W-49-4)
1302 (OPTIONAL)
* WITH POWER WINDOWS
AND POWER LOCKS
8040ccf4 J968W-9
RIGHT DOOR
•Z3 18BK/0R * J A M B SWITCH
C8W-49-4)
G303
RIGHT LEFT
LEFT O U T B O A R D CENTER RIGHT OUTBOARD VISOR/ VISOR/
IDENTIFICATION IDENTIFICATION IDENTIFICATION VANITY VANITY
LAMP LAMP LAMP LAMP LAMP
(8W-50-6) (8W-50-6) (8W-50-6) (8W-44-4) C8W-44-4)
Z4
18BK
•Z4 18BK- •Z4 18BK-
Z4 Z4
LEFT OUTBOARD RIGHT OUTBOARD 20BK 20BK
CLEARANCE LAMP •Z4 18BK- •Z4 18BK- CLEARANCE LAMP
(8W-50-6) S318* (8W-50-6)
8W-70-40
C3S3 C352
DAY/NIGHT
MIRROR
(8W-44-9)
WITH
HIGH-LINE
CLUSTER
WITH WITH
LOW-LINE HIGH-LINE
CLUSTER CLUSTER
G3Q4
OVERHEAD
MAP/ - ) OVERHEAD
COURTESY CONSOLE
LAMP
(8W-49-5)
* WITH CLEARANCE AND I.D. LAMPS

** WITH CONSOLE
8040ccf5 J968W-9
BR 8W - 20 CHARGING SYSTEM 8W - 20 -1
8W-20 C H A R G I N G S Y S T E M
DESCRIPTION AND OPERATION The- Powertrain Control Module (PCM) has an

internal voltage regulator that controls generator
CHARGING SYSTEM output. Circuit K20 connects the generator and PCM,
The charging system is an integral part of the bat cavity BIO. The PCM controls the generator field on
tery and starting systems. Because all these systems the K20 circuit.
work in conjunction, diagnose and test them together. When the engine operates and there is current in
Circuit AO from the battery connects to a bus bar the generator field, the generator produces a B+ volt
in the Power Distribution Center (PDC). Circuit A l l age. The generator supplies B+ voltage to the battery
connects to the PDC bus bar and the output terminal through the A l l and AO circuits.
of the generator. A fuse in the PDC between AO and
HELPFUL INFORMATION
A l l circuits protects the charging system. Circuit Z l
provides ground for the generator. • Check the 120 amp fuse located in the PDC
On the diesel engine applications an additional • From the ASD relay, circuit A142 splices to sup
battery is used. Circuit AO connects between the bat ply voltage to the fuel injectors, ignition coil, fuel
tery positive terminals of the batteries. pump module, and the heated oxygen sensors on gas
When the ignition switch is in either the START or oline powered engines
RUN positions, i t connects battery voltage from cir
cuit A l to the A21 circuit. Circuit A21 powers circuit SCHEMATICS AND DIAGRAMS
F18 through fuse 9 in the fuse block. Circuit F18 con
nects to the coil side of the Automatic Shut Down WIRING DIAGRAM INDEX
(ASD) relay. Circuit A l originates in the PDC and is
connected to battery voltage. A 40 amp fuse in cavity
this section of the wiring diagrams. I f the component
3 of the PDC protects the A l circuit.
you are looking for is not found here, refer to section
When the ASD relay energizes, i t connects circuit
8W-02 for a complete list of all components shown in
A16 from the PDC to circuit A142. Circuit A142
the wiring diagrams.
splices to connect to the generator connector supply
ing battery voltage to the generator field.
8W - 20 - 2 — — — — ^ — — 8W-20 CHARGING SYSTEM • — ^ — - BR
DIAGRAM INDEX
1
Component Page • Component •' Page
Battery 8W-20-3, 4 Powertrain Control Module 8W-20-3,4
Fuse (Gen) (PDC) 8W-20-3, 4 Right Battery . . . . . . 8 W - 2 0 - 4
Generator........... 8W-20-3, 4
8040ccf7 J968W-9
BR* 8W-20 CHARGING SYSIEii 8W - 20 - 3
(WITH GAS ENG)
ENGINE
STARTER
MOTOR
(8W-21-3)
SPLICE
S14S AO 20BK ZO ZO
(8W-70-21) 8BK 10BK
G110 Gill G109
8W-15-9 i 1 8W-15-9 i 1 8W-15-9
AUTOMATIC
S H U T DOWN
RELAY
(8W-3G-12)
(8W-11-10)
C137 ! POWERTRAIN
ASD CONTROL
C12 RELAY
MODULE
SENSE
A142
16DG
OR GENERATOR
FIELD
C127 S138 DRIVER
-<f- A142 14DG/0R- 8W-70-17 BIO
C136
A142 K20
14DG 18DG
OR
S135
A142 14DB- 8W-70-15
S134
8W-70-14
K20 18DG-
J968W-9
8W-20-4 8W-20 CHARGING SYSTEM BR
(WITH DIESEL ENG)
AUTOMATIC
SPLICE S H U T DOWN
STARTER S14S RELAY
MOTOR (8W-70-21) (8W-30-12)
(8W-21-4) C8W-11-
C137 POWERTRAIN
ASD
CONTROL
C12 RELAY
SENSE
MODULE
(3) CIS1
GENERATOR
GENERATOR
FIELD
DRIVER
BIO
C136
C151 T K20
-A142
I 4 I J (2)
14DB 18DG
S134
8W-70-14
-K20 18DG-
(4) C151 (1)

Y
zi
6BK
1113
# 8W-15-10
J968W-9
8W - 21 STARTING SYSTEM 8W - 21 -1
8W-21 STARTING SYSTEM
DESCRIPTION AND OPERATION Circuit AO from the battery is triple crimped at the
positive battery post. One branch of circuit AO (bat
AUTOMATIC TRANSMISSION tery positive cable) connects to the engine starter
- The Power Distribution Center (PDC) supplies bat motor. Another branch of circuit AO supplies voltage
tery voltage to the engine starter motor solenoid on to a bus bar in the PDC. Fuse 2 in the PDC connects
circuit T40 when the coil side of the engine starter to the bus bar and protects circuit A2. Circuit A2
motor relay energizes. splices and connects to the contact side of the engine
Circuit AO from the battery is triple crimped at the starter motor relay.
positive battery post. One branch of circuit AO (bat When the ignition switch is in the START position,
tery positive cable) connects to the starter motor. The it connects circuit A l from fuse 3 in the PDC to cir
other AO branch supplies voltage to a bus bar in the cuit A41. Circuit A41 connects to circuit T141
PDC. Fuse 2 (40 amp) connects to the bus bar and through the clutch pedal position switch. Circuit
protects circuit A2. Circuit A2 connects to the contact T141 supplies battery voltage to the coil side of the
side of the engine starter motor relay. engine starter motor relay when the operator presses
When the ignition switch is in the START position the clutch pedal and the clutch pedal position switch
it connects circuit A l from fuse 3 in the PDC to cir CLOSES. Ground for the coil side of the engine
cuit A41. Circuit A41 connects to circuit T141 at the starter motor relay is supplied on circuit T41. This
bypass jumper. Circuit T141 supplies battery voltage circuit is connected with circuit Z12. Circuit Z12 con
to the coil side of the engine starter motor relay. nects to ground.
Ground for the coil side of the starter motor relay is When the starter motor relay energizes and the
supplied by the case grounded PARK/NEUTRAL contacts CLOSE, circuit T40 supplies battery voltage
position switch. Circuit T41 connects the coil side of to the starter motor solenoid. Circuit AO from the
the relay to the PARK/NEUTRAL position switch. battery supplies voltage to the starter motor when
When the starter motor relay energizes and the the solenoid energizes.
contacts CLOSE, circuit T40 supplies battery voltage
to the starter motor solenoid. Circuit AO from the HELPFUL INFORMATION
battery supplies voltage to the starter motor when • Check the fuse located in cavity 2 of the PDC.
the solenoid energizes. • On diesel engines the T40 circuit is spliced and
supplies power to the coil side of the fuel shut down
HELPFUL INFORMATION relay.
• Check the fuse located in cavity 2 of the PDC
• The PARK/NEUTRAL position switch CLOSES
SCHEMATICS AND DIAGRAMS
when the transmission is in either the PARK or
NEUTRAL positions.
WIRING DIAGRAM INDEX
• On diesel engines the T40 circuit is spliced and
The following index covers all components found i n
supplies power for the fuel shut down relay.
MANUAL TRANSMISSION
8W-02 for a complete list of all components shown i n
The Power Distribution Center (PDC) supplies bat
tery voltage to the engine starter motor solenoid on
circuit T40 when the coil side of the engine starter
motor relay energizes.
8W-21 -2 8W-21 STARTING SYSTEM BR
DIAGRAM INDEX
Bypass Jumper 8W-21-3, 4 Fuse 2 (PDC) 8W-21-3.4
Clutch Pedal Position Switch 8W-21-3, 4 Fuse 3 (PDC) 8W-21-3.4
Engine Starter Motor 8W-21-3, 4 Ignition Switch 8W-21-3.4
Engine Starter Motor Relay 8W-21-3,4 Park/Neutral Position Switch 8W-21-3,4
8040ccfc J968W-9
mm 8W-21 STARTING S Y S • c m 8W - 21 - 3
(WITH GAS ENG)
"1 ENGINE
BATTERY C181 STARTER
POSITIVE MOTOR
AO 6RD- I W j » • • -j
TERMINAL
(8W-20 3} (B)
3°) PULL-ON ( ^ M
AO
20BK
T40 (A)
12BR BLACK mub—
HOLD-ON
SPLICE
$148 C119
C8W-70-21) C125
POWER T40 T41

DISTRIBUTION 12BR 22BK
CENTER WT
4
(87)>j< (85) C180
ENGINE
FUSE FUSE
STARTER Z12 T41
3 2
20BK 20BK
MOTOR
• 40A
RELAY WITH TN WT
• 40A
MAN S151 S141
(3) Vr_
(2)
TRANS
C180 8W-70-22 8W-70-19
(30) ^ j 8 6 ) C180
Al A2
A2 Z12 T41
T141
12RD 12PK S146 10BK 18BK
12PK 14YL
BK 8W-7Q-201 BK RD TN WT
| S150
8W-70-22
i- C133 Z12
14BK
TN
Gilt
III8W-15-11
(2) : C169
PARK/
WITH
NEUTRAL
- MAN
TRANS POSITION
SWITCH
T141 T141 I 4 i
14YL 14YL CASE
RD RD GROUND
CLUTCH PEDAL
POSITION SWITCH
CI32 CI32
-)} A41 1 8 D B / Y L -
(i) (2)
C132 « ^ C132
-<f-f T141 20YL/RD}--)) —A41 18DB/YL"

(1) (2)
C133
-A41 18DB/YL-
8040ccfe J968W-9
8W - 21 - 4 8W-21 STARTING SYSTEM mm
(WITH DIESEL ENG)
ENGINE
LEFT STARTER
BATTERY MOTOR
POSITIVE AO 00ERD-
<
:
«r—9 1
TERMINAL
C8W-20-4) BLACK
-T40 12BR
PULL-ON
L-ON Q
RIGHT
BATTERY C119 KMMJ—-
POSITIVE HOLD-ON
TERMINAL T40
(WITH 1 SPLICE
12BR
DIESEL S148
ENG) C8W-70-21) S113
C8W-20-4) 8W-70-7 C127
F U E L SHUT
-T40 12BR- -T40 12BR- DOWN RELAY
(8W-30-47)
POWER C12S
T41 22BK/WT—))—
Z12
20BK T41
WITH TN 20BK
MAN -- • I S152 WT
TRANS 8W-70-22
S141
Z12
14BK 8W-70-19
TN
| S142
8W-70-19 T41
I 18BK
Z12 WT
14BK
TN
lilt
(2) C169
8W-15-12
PARK/
WITH NEUTRAL
- MAN POSITION
TRANS SWITCH
CASE
CLUTCH PEDAL GROUND
POSITION SWITCH
C132 C132
-A41 18DB/YL-
(1) (2)
BYPASS JUMPER C132

« — ^ T 1 4 1 20YL/RD^-»- •A41 18DB/YL"
(2)
C133
-A41 18DB/YL-
8040d001 J968W-9
BR 8W - 30 FUEL/IGNITION SYSTEMS 8W - 30 -1
8W-30 FUEL/IGNITION SYSTEMS
INDEX
page page
DESCRIPTION AND OPERATION HEATED OXYGEN SENSORS 3

AUTOMATIC SHUT DOWN (ASD) RELAY 2 IDLE AIR CONTROL MOTOR 6
BATTERY FEED 1 IGNITION COIL—V-10 ENGINES 6
BATTERY TEMPERATURE SENSOR 1 IGNITION COIL—V-6 AND V-8 ENGINES 6
CAMSHAFT POSITION SENSOR 4 IGNITION SWITCH 1
CRANKSHAFT POSITION SENSOR .3 INTAKE AIR TEMPERATURE SENSOR 5
DATA LINK CONNECTOR 2 INTAKE AIR TEMPERATURE SENSOR—DIESEL
DUTY CYCLE EVAP/PURGE SOLENOID 6 ENGINE 7
EGR ENGINE COOLANT TEMPERATURE INTAKE MANIFOLD AIR HEATER R E L A Y S -
SENSOR—DIESEL ENGINE 8 DIESEL ENGINE 8
EGR INTAKE AIR TEMPERATURE S E N S O R - MALFUNCTION INDICATOR LAMP (MIL) 6
DIESEL ENGINE 8 MANIFOLD ABSOLUTE PRESSURE SENSOR . . . 4
EGR SOLENOID 6 OUTPUT SHAFT SPEED SENSOR—FOUR
EGR SOLENOID—DIESEL ENGINE 8 SPEED AUTOMATIC TRANSMISSION 7
ENGINE COOLANT TEMPERATURE SENSOR . . . 4 PARK/NEUTRAL POSITION SWITCH 5
ENGINE SPEED SENSOR—DIESEL ENGINE 7 SERVICE REMINDER INDICATOR LAMP 7
FUEL HEATER RELAY—DIESEL ENGINE 7 TACHOMETER 7
FUEL INJECTORS 5 THROTTLE POSITION SENSOR 4
FUEL INJECTORS—V-10 ENGINES 5 THROTTLE POSITION SENSOR—DIESEL
FUEL PUMP MODULE 2 ENGINE 4
FUEL PUMP MODULE—DIESEL ENGINE 2 VEHICLE SPEED SENSOR 3
FUEL PUMP RELAY 2 WATER-IN-FUEL SENSOR—DIESEL ENGINE . . . 7
FUEL SHUT DOWN RELAY—DIESEL ENGINE . . . 7 SCHEMATICS AND DIAGRAMS
GROUND 1 WIRING DIAGRAM INDEX 8
DESCRIPTION AND OPERATION connects to the fuse block and feeds circuits F30, L5,
X12, and V6. Separate fuses protect each circuit.
IGNITION SWITCH
When the ignition switch is in the RUN position, it BATTERY FEED
connects circuit A2 from fuse 2 in the Power Distri Circuit A14 from fuse 8 in the Power Distribution
bution Center (PDC) to circuit A22. Circuit A22 con Center (PDC) supplies battery voltage to cavity A22
nects to the fuse block. Through the fuse block, of the Powertrain Control Module (PCM).
circuit A22 feeds circuits A20, L10, F23, C I and F21.
Circuits A20, L10, F23, and C I are protected by sep GROUND
arate fuses. A circuit breaker protects circuit F21. Circuit Z12 connects to cavities A31 and A32 of the
When the ignition switch is in the START or RUN Powertrain Control Module (PCM). The Z12 circuit
position, it connects circuit A l from fuse 3 in the provides ground for PCM internal drivers that oper
PDC to circuit A21. Circuit A21 powers circuits F18, ate high current devices like the injectors and igni
F12, and F14 through the fuse block. Separate fuses tion coil.
protect each circuit.
In the START position, the ignition switch connects HELPFUL INFORMATION
circuit A l from fuse 3 in the PDC to circuit A41. Cir I f the system loses ground for the Z12 circuits the
cuit A41 connects to either the clutch pedal position vehicle will not operate.
sensor or the clutch pedal position switch bypass
jumper. Also in the START position, the ignition BATTERY TEMPERATURE SENSOR
switch connects circuit G9 to ground. The Powertrain Control Module (PCM) determines
In the ACCESSORY or RUN position, the ignition battery temperature on circuit K118. Circuit K118
switch connects circuit A l to circuit A31. Circuit A31 connects, the PCM' to the battery temperature sensor.
Circuit K4 provides ground for the sensor. Circuit
8W - 30 - 2 8W - 30 FUEL/IGNITION SYSTEMS BR
D E S C R I P T I O N AMD O P E R A T I O N (Continued)
K118 connects to cavity C15 of the PCM. Circuit K4 FUEL PUMP MOTOR
connects to cavity A4. When the fuel pump relay contacts close, circuit
A61 feeds the fuel pump motor. Circuit Z13 provides
DATA LINK CONNECTOR ground for the fuel pump motor.
Circuit M l supplies battery voltage to the data
link connector. Circuit M l originates at cavity 7 of FUEL LEVEL SENSOR
Joint Connector B. The fuel level sensor is a variable resistor. Circuit
Circuit D20 connects to cavity C29 of the Power- G4 connects the fuel level sensor to the fuel gauge in
train Control Module (PCM). Circuit D20 is the SCI the instrument cluster. Circuit F14 from fuse 12 in
receive circuit for the PCM. the fuse block supplies voltage to the fuel gauge. The
Circuit D21 connects to. cavity C27 of the 'PCM. fuel level sensor draws voltage from circuit F14
Circuit D21 is the SCI transmit circuit for the PCM. through the fuel gauge on circuit G4. Circuit Z l l pro
Circuits Z l l and Z12 provide ground for' the data vides the ground path for the fuel level sensor.
link connector. As current flows through the coils in the fuel
gauge, it creates a magnetic field. One of the coils in
AUTOMATIC SHUT DOWN (ASD) RELAY the gauge receives fixed current. The other coil is
When the ignition switch is in the START or RUN connected to the level sensor. The magnetic field con
position, it connects circuit A l from fuse 8 in the trols the position of the fuel gauge pointer.
Power Distribution Center (PDC) to circuit A21. Cir The fuel level, sensor contains a variable resistor.
cuit A21 powers circuit F18 through fuse 9 in the As the position of the float arm on the fuel level sen
fuse block. Circuit F18 supplies battery voltage to the sor changes, the resistor changes the current flow
coil side of the ASD relay. The Powertrain Control through the second coil in the fuel gauge. A change in
Module (PCM) provides the ground path for the coil current flow alters the magnetic field in the fuel
side of the relay on circuit K51. Circuit K51 connects gauge, which changes the pointer position.
to cavity C3 of the PCM. Circuit K104 from the level sensor connects to cir
When the PCM grounds the ASD relay, the relay cuit K226. Circuit K226 connects to cavity C26 of the
contacts close and connect circuit A16 from fuse 4 in Powertrain Control Module (PCM). Circuit K226 pro
the PDC to circuit A142. Circuit A142 splices to sup vides the fuel level input to the PCM. Circuit K4 pro
ply voltage to the fuel injectors, ignition coil, and vides ground for the level sensor signal.
heated oxygen sensors. Circuit A142 also connects to
cavity C12 of the PCM. FUEL PUMP MODULE—DIESEL ENGINE
The in-tank fuel pump' module used with diesel
FUEL PUMP RELAY engines contains the fuel level sensor. The diesel
Circuit A14 from fuse 8 in the Power Distribution engine does not use an in-tank electrical fuel pump.
Center (PDC) supplies battery voltage to the contact For fuel pump module information, refer to Group
side of the fuel pump relay. Circuit A21 from the 14, Fuel System.
ignition switch powers circuit F18 through 9 in the
fuse block. Circuit F18 supplies battery voltage to the FUEL LEVEL SENSOR
coil side of the Automatic Shut Down (ASD) and fuel The fuel level sensor is a variable resistor. Circuit
pump relays. The Powertrain Control Module (PCM) G4 connects the fuel level sensor to the fuel gauge in
provides the ground path for the coil side of the fuel the instrument cluster. Circuit F14 from fuse 12 in
pump relay on circuit K31. Circuit K31 connects to the fuse block supplies voltage to the fuel gauge. The
cavity C19 of the PCM connector. fuel level sensor draws voltage from circuit F14
When the PCM grounds the fuel pump relay, the through the fuel gauge on circuit G4. Circuit Z l l pro
contacts CLOSE and connect circuits A14 and A61. vides the ground path for the fuel level sensor.
Circuit A61 supplies voltage to the fuel pump motor As current flows through the coils in the fuel
(part of the in-tank fuel pump module). gauge, it creates a magnetic field. One of the coils in
the gauge receives fixed current. The other coil is
HELPFUL INFORMATION " •' ' ' connected to the level sensor. The magnetic field con
Circuit A14 also connects to cavity A22 of the PCM. trols the position of the fuel gauge pointer.
The fuel level sensor contains a variable resistor.
FUEL PUMP MODULE . As the position of the float arm on the fuel level sen
The in-tank fuel pump module contains the fuel sor changes, the resistor changes the current flow
pump motor and the fuel level sensor. For fuel pump through the second coil in the fuel gauge. A change in
module information, refer to Group 14, Fuel System. current flow alters the magnetic field in the fuel
gauge, which changes the pointer position.
8W - 30 FUEL/IGNITION SYSTEMS 8W - 30 - 3
VEHICLE SPEED SENSOR V-fO ENGINES

Circuit K7 supplies 5 volts from the Powertrain Vehicles with the V-10 engine built for sale in the
Control Module (PCM) to the vehicle speed sensor. State of California use four heated oxygen sensors.
The K7 circuit connects to cavity B31 of the PCM All other V-10 equipped vehicles use two heated oxy
connector. gen sensors.
Circuit G7 from the vehicle speed sensor provides Circuit K141 delivers the signal from the left
an input signal to the PCM. The G7 circuit connects heated oxygen sensor to the Powertrain Control Mod
to cavity B27 of the PCM. ule (PCM). Circuit K141 connects to cavity A24 of the
The PCM provides a ground for the vehicle speed PCM. Circuit K41 delivers the signal from the right
sensor signal (circuit G7) through circuit K4. Circuit sensor and connects to cavity A26 of the PCM.
K4 connects to cavity A4 of the PCM. On California vehicles, Circuit K441 delivers the
signal from the pre-catalyst heated oxygen sensor to
HELPFUL INFORMATION the PCM. Circuit K441 connects to cavity A29 of the
Circuit K4 splices to supply ground for the signals PCM. Circuit K341 delivers the signal from the post
from the following: catalyst sensor and connects to cavity A25 of the
• Heated oxygen sensors PCM. ,
® Camshaft position sensor The PCM provides a ground for the heated oxygen
• Crankshaft position sensor sensor signals (circuits K41, K141, K341 and K441)
• Throttle position sensor through circuit K4. Circuit K4 connects to cavity A4
• Manifold absolute pressure sensor of the PCM connector.
• Engine coolant temperature sensor Circuit Z l l provides a ground for the heater circuit
• Intake air temperature sensor in the sensors.
HEATED OXYGEN SENSORS HELPFUL INFORMATION

When the Automatic Shut Down (ASD) relay con • Along with supplying voltage to the ASD relay
tacts CLOSE, they connect circuits A16 and A142. contacts, circuit A14 connects to cavity A22 of the
Circuit A142 splices to supply voltage to the heated PCM.
oxygen sensors. • Circuit A142 splices to supply voltage to the fuel
injectors and ignition coil(s).
V-6 AND V-8 LIGHT DUTY ENGINES Circuit K4 splices to supply ground for the signals
Circuit K141 delivers the signal from the upstream from the following:
heated oxygen sensor to the Powertrain Control Mod • Camshaft position sensor
ule (PCM). Circuit K141 connects to cavity A24 of the • Crankshaft position sensor
PCM. Circuit K341 delivers the signal from the • Intake air temperature sensor
downstream sensor and connects to cavity A25 of the • Throttle position sensor
PCM. • Manifold absolute pressure sensor
The PCM provides a ground for the heated oxygen • Engine coolant temperature sensor
sensor signals (circuits K141 and K341) through cir • Vehicle speed sensor
cuit K4. Circuit K4 connects to cavity A4 of the PCM
connector. CRANKSHAFT POSITION SENSOR
Circuit Z l l provides a ground for the heater circuit The Powertrain Control Module (PCM) supplies 5
in the sensors. volts to the crankshaft position sensor on circuit KB.
Circuit K6 connects to cavity A17 of the PCM.
5.9L V-8 HEAVY DUTY ENGINE The PCM receives the crankshaft position sensor
Circuit K41 delivers the signal from the upstream signal on circuit K24. Circuit K24 connects to cavity
heated oxygen sensor to the Powertrain Control Mod A8 of the PCM.
ule (PCM). Circuit K41 connects to cavity A24 of the The PCM provides a ground for the crankshaft
PCM. Circuit K241 delivers the signal from the position sensor (circuit K24) through circuit K4. Cir
downstream sensor and connects to cavity A26 of the cuit K4 connects to cavity A4 of the PCM connector.
PCM.
The PCM provides a ground for the heated oxygen HELPFUL INFORMATION
sensor signals (circuits K41 and K241) through cir • Circuit KB splices to supply 5 volts to the cam
cuit K4. Circuit K4 connects to cavity A4 of the PCM shaft position sensor.
connector. Circuit K4 splices to supply ground for the signals
Circuit Z l l provides a ground for the heater circuit from the following:
in the sensors. • Heated oxygen sensors
• Camshaft position sensor
8W - 3 0 - 4 8W - 31 FUEL/IGNITION SYSTEMS BR
DESCRIPTION A N D OPERATION (Continued)
• Intake air temperature sensor sor (TPS). Circuit K6 connects to cavity A17 of the
• Throttle position sensor PCM.
• Manifold absolute pressure sensor Circuit K22 delivers the TPS signal to the PCM.
• Engine coolant temperature sensor Circuit K22 connects to cavity A23 of the PCM.
• Vehicle speed sensor The PCM provides a ground for the TPS signal
(circuit K22) through circuit K4. Circuit K4 connects
CAMSHAFT POSITION SENSOR to cavity A4 of the PCM.
The Powertrain Control Module (PCM) supplies 5
volts to the camshaft position sensor on circuit K6. HELPFUL INFORMATION
Circuit KB connects to cavity A17 of the PCM. Refer to Group 14 for TPS operation.
The PCM receives the camshaft position sensor sig Circuit K6 splices to supply 5 volts to the manifold
nal on circuit K44. Circuit K44 connects to cavity absolute pressure sensor, crankshaft position sensor
A18 of the PCM. and camshaft position sensor.
The PCM provides a ground for the camshaft posi Circuit K4 splices to supply ground for the signals
tion sensor (circuit K44) through circuit K4. Circuit from the following:
K4 connects to cavity A4 of the PCM connector. • Heated oxygen sensors
• Camshaft position sensor
HELPFUL INFORMATION • Crankshaft position sensor
• Circuit K 6 splices to supply 5 volts to the crank • Intake air temperature sensor
shaft position sensor. • Manifold absolute pressure sensor
Circuit K4 splices to supply ground for the signals • Engine coolant temperature sensor
from the following: • Vehicle speed sensor
• Heated oxygen sensors
» Crankshaft position sensor THROTTLE POSITION SENSOR—DIESEL ENGINE
• Intake air temperature sensor From the Powertrain Control Module (PCM), cir
• Throttle position sensor cuit K6 supplies 5 volts to the Throttle Position Sen
• Manifold absolute pressure sensor sor (TPS). Circuit K6 connects to cavity A17 of the
• Engine coolant temperature sensor PCM.
• Vehicle speed sensor Circuit K22 delivers the TPS signal to the PCM.
Circuit K22 connects to cavity A23 of the PCM. Cir
ENGINE COOLANT TEMPERATURE SENSOR cuit K22 also splices to cavity 3 of the EGR control
The engine coolant temperature sensor provides an module.
input to the Powertrain Control Module (PCM) on The PCM provides a ground for the TPS signal
circuit K2. From circuit K2, the engine coolant tem (circuit K22) through circuit K4. Circuit K4 connects
perature sensor draws up to 5 volts from the PCM. to cavity A4 of the PCM.
The sensor is a variable resistor. As engine coolant
temperature changes, the resistance in the sensor HELPFUL INFORMATION
changes, causing a change in current draw. The K2 Refer to Group 14 for TPS operation.
circuit connects to cavity A16 of the PCM. Circuit K4 splices to supply ground for the signals
The PCM provides a ground for the engine coolant from the following:
temperature sensor signal (circuit K2) through circuit • Battery Temperature Sensor
K4. Circuit K4 connects to cavity A4 of the PCM. • Crankshaft Position Sensor
• Water-In-Fuel Sensor
HELPFUL INFORMATION • Vehicle speed sensor
Circuit K4 splices to supply ground for the signals
from the following: MANIFOLD ABSOLUTE PRESSURE SENSOR
• Heated oxygen sensors From the Powertrain Control Module (PCM), cir
• Camshaft position sensor cuit K6 supplies 5 volts to the Manifold Absolute
• Crankshaft position sensor Pressure (MAP) sensor. Circuit K6 connects to cavity
• Intake air temperature sensor A17 of the PCM.
• Throttle position sensor Circuit K l delivers the MAP signal to the PCM.
• Manifold absolute pressure sensor Circuit K l connects to cavity A27 of the PCM.
• Vehicle speed sensor The PCM provides a ground for the MAP sensor
signal (circuit K l ) through circuit K4. Circuit K4 con
THROTTLE POSITION SENSOR nects to cavity A4 of the PCM.
From the Powertrain Control Module (PCM), cir
cuit K6 supplies 5 volts to the Throttle Position Sen
BR 8W - 30 FUEL/IGNITION SYSTEMS 8W.-30-5
HELPFUL INFORMATION FUEL INJECTORS
Refer to Group 14 for'MAP sensor operation. When the Automatic Shut Down (ASD) relay con
Circuit KB splices to supply 5 volts to the Throttle tacts close, they connect circuits A16 and A142. Cir
Position Sensor (TPS), camshaft position sensor, and cuit A142 supplies voltage to the fuel injectors. Each
crankshaft position sensor. injector has a separate ground circuit controlled by
Circuit K4 splices to supply ground for the signals the Powertrain Control Module (PCM).
from the following: Circuit K l l provides ground for injector number
• Heated oxygen sensors one. The K l l circuit connects to cavity B4 of the
® Camshaft position sensor PCM.
© Crankshaft position sensor Circuit K12 provides ground for injector number
• Intake air temperature sensor two. The K12 circuit connects to cavity B15 of the
• Throttle position sensor PCM.
• Engine coolant temperature sensor Circuit K13 * provides ground for injector number
• Vehicle speed sensor three. The K13 circuit connects to cavity B5 of the
PCM.
INTAKE AIR TEMPERATURE SENSOR Circuit K14 provides ground for injector number
The intake air temperature sensor provides an four. The K14 circuit connects to cavity B16 of the
input to the Powertrain Control Module (PCM) on PCM.
circuit K21. Circuit K21 connects to cavity A15 of the Circuit K38 provides ground for injector number
PCM. five. The K38 circuit connects to cavity B6 of the
From circuit K21, the intake air temperature sen PCM.
sor draws voltage from the PCM. The sensor is a ' Circuit K58 provides ground for injector number
variable resistor. As intake air temperature changes, six. The K58 circuit connects to cavity B12 of the
the resistance in the sensor changes, causing a PCM.
change in current draw. On the 5.2L and 5.9L engines, circuit K26 provides
The PCM provides a ground for the intake air tem ground for injector number seven. The K26 * circuit
perature sensor signal (circuit K21) through circuit connects to cavity B2 of the PCM.
K4. Circuit K4 connects to cavity A4 of the PCM. Also on the 5.2L and 5.9L engines, circuit K28 pro
vides ground for injector number eight. The K28 cir
HELPFUL INFORMATION cuit connects to cavity B13 of the PCM.
from the following: HELPFUL INFORMATION
• Heated oxygen sensors • Circuit A142 splices to supply voltage to the fuel
• Camshaft position sensor injectors, ignition coil, PCM, generator, and heated
• Crankshaft position sensor oxygen sensors.
• Throttle position sensor • For information about fuel injector operation,
• Manifold absolute pressure sensor refer to Group 14. • ' "
® Engine coolant temperature sensor
• Vehicle speed sensor FUEL INJECTORS—V-10 ENGINES
When the Automatic Shut Down (ASD) relay con
PARK/NEUTRAL POSITION SWITCH tacts close, they connect circuits A16 and A142. Cir
When closed, the case-grounded Park/Neutral posi cuit A142 supplies voltage to the fuel injectors. The
tion switch provides a ground path on circuit T41 for Powertrain Control Module (PCM) provides the
the coil side of the engine starter motor relay. Circuit ground for the injectors.
A41 from the ignition switch provides battery voltage • Circuit K l l provides * ground for injector number
to the coil side of the relay. one. The K l l circuit connects to cavity B4 of the
Circuit T41 splices to cavity A6 of the Powertrain PCM.
Control Module (PCM). The Park/Neutral position Circuit K12 provides ground for injector number
switch provides an input to the PCM. two. The K12 circuit connects to cavity B15 of the
PCM.
HELPFUL INFORMATION . . Circuit K13 provides ground for injector number
• In the START position, the ignition switch con three. The K13 circuit connects to cavity B5 of the
nects circuit A l from the power distribution center PCM.
(PDC) to circuit A41. A 40 amp fuse i n cavity 3 of the Circuit K14 provides ground for injector number
PDC protects circuits A l and A41. four. The K14 circuit connects to cavity B16 of the
• The Park/Neutral position switch and back-up PCM.
lamp switch are molded together.
8W - 30 - 6 8W - 30 FUEL/IGNITION SYSTEMS BR
Circuit K38 provides ground for injector number IDLE AIR CONTROL MOTOR
five. The K38 circuit connects to cavity B6 of the The Powertrain Control Module (PCM) operates
PCM. the Idle Air Control motor through four circuits; K39,
Circuit K58 provides ground for injector number K40, K59, and K60. Each circuit connects to separate
six. The K58 circuit connects to cavity B12 of the cavities in the PCM connector.
PCM. • Circuit K39 connects to cavity A19 of the PCM
Circuit K26 provides ground for injector number connector.
seven. The K26 circuit connects to cavity B2 of the • Circuit K40 connects to cavity A l l of the PCM
PCM. connector.
Circuit K28 provides ground for injector number • Circuit K59 connects to cavity A20 of the PCM
eight. The K28 circuit connects to cavity B13 of the connector.
PCM. • Circuit K60 connects to cavity A10 of the PCM
Circuit K115 provides ground for injector nine. The connector.
K115 circuit connects to cavity B3 of the PCM.
Circuit K116 provides ground for injector ten. The DUTY CYCLE EVAP/PURGE SOLENOID
K116 circuit connects to cavity B14 of the PCM. The Powertrain Control Module (PCM) operates
the EVAP/Purge solenoid by providing a ground path
IGNITION COIL—V-6 AND V-8 ENGINES on circuit K52. Circuit K52 connects to PCM cavity
When the Automatic Shut Down (ASD) relay con C20. Circuit F18 supplies battery voltage to the
tacts close, they connect circuits A16 and A142. Cir EVAP/Purge solenoid.
cuit A142 splices to supply voltage to the ignition
coil. The Powertrain Control Module (PCM) controls HELPFUL INFORMATION
the ground path for the ignition coil on circuit K19. • I n the RUN or START position, the ignition
Circuit K19 connects to cavity A7 of the PCM. switch connects circuit A l from the Power Distribu
tion Center (PDC) and circuit A21. Circuit A21 feeds
HELPFUL INFORMATION circuit F18 through fuse 9 in the fuse block.
Circuit A142 splices to supply voltage to the fuel • Circuit F18 splices to supply battery voltage to
injectors, PCM, generator, and heated oxygen sen the EGR solenoid and connects to cavity A2 of the
sors. PCM.
IGNITION COIL—V-10 ENGINES EGR SOLENOID

V-10 engines use two ignition coil packs. One coil The Powertrain Control Module (PCM) operates
pack supplies spark to cylinders 5, 8, 9, and 10. The the EGR solenoid by providing a ground path on cir
other coil pack connects to cylinders 1, 2, 3, 4, 6, and cuit K35. Circuit K35 connects to PCM cavity B32.
7. Circuit F18 supplies battery voltage to the EGR sole
When the Powertrain Control Module (PCM) noid.
grounds the Automatic Shut Down (ASD) relay, the
contacts close and connect circuits A16 and A142. HELPFUL INFORMATION
Circuit A142 supplies battery voltage to the ignition In the RUN or START position, the ignition switch
coil packs. The PCM provides ground for each indi connects circuit A l from the Power Distribution Cen
vidual coil. ter (PDC) to circuit A21. Circuit A21 feeds circuit F18
The PCM controls the ground path for the coil that through fuse 9 in the fuse block.
supplies spark to cylinders 1 and 6 on circuit K19. Circuit F18 splices to supply battery voltage to the
Circuit K19 connects to cavity A7 of the PCM. EVAP/Purge solenoid and connects to cavity A2 of the
The PCM controls the ground path for the coil that PCM.
supplies spark to cylinders 2 and 3 on circuit K43.
Circuit K43 connects to cavity A5 of the PCM. MALFUNCTION INDICATOR LAMP (MIL)
The PCM controls the ground path for the coil that The PCM provides ground for the instrument clus
supplies spark to cylinders 8 and 9 on circuit K18. ter malfunction indicator lamp on circuit G3. Circuit
Circuit K18 connects to cavity A3 of the PCM. G3 connects to cavity C17 of the PCM. Circuit F14
The PCM controls the ground path for the coil that provides voltage for the lamp. The M I L displays the
supplies spark to cylinders 4 and 7 on circuit K32. message CHECK ENGINE when illuminated.
Circuit K32 connects to cavity A l of the PCM. For information regarding diagnostic trouble code
The PCM controls the ground path for the coil that access using the M I L lamp, refer to Group 14, Fuel
supplies spark to cylinders 5 and 10 on circuit K17. Systems.
Circuit K17 connects to cavity A9 of the PCM
BR 8W - 30 FUEL/IGNITION SYSTEMS 8W - 30 - 7
D E S C R I P T I O N A N DOPERATION (Continued)
SERVICE REMINDER INDICATOR LAMP the resistance in the sensor changes, causing a
The Powertrain Control Module (PCM) provides change in current draw.
ground for the Service Reminder Indicator (SRI) The PCM provides a ground for the intake air tem
lamp on circuit G24. Circuit G24 connects to cavity perature sensor signal (circuit K21) through circuit
C18 of the PCM. Circuit F14 provides voltage for the K4. Circuit K4 connects to cavity A4 of the PCM.
lamp. The SRI lamp displays the message MAINT
REQ'D. HELPFUL INFORMATION
TACHOMETER from the following:
The tachometer module in the instrument cluster • Water-in-fuel sensor
operates the tachometer. The Powertrain Control • Engine speed sensor
Module (PCM) supplies the signal for the tachometer • Throttle position sensor
on circuit G21. Circuit G21 connects to cavity C31 of • Battery temperature sensor
the PCM. • Vehicle speed sensor
OUTPUT SHAFT SPEED SENSOR—FOUR SPEED ENGINE SPEED SENSOR—DIESEL ENGINE

Circuit K6 supplies 5 volts from the Powertrain
AUTOMATIC TRANSMISSION
Control Module (PCM) to the engine speed sensor.
* The output shaft speed sensor generates a signal
The K6 circuit connects to cavity A17 of the PCM
indicating the speed of the transmission output shaft.
connector.
Circuits T13 and T14 connect the sensor to the Pow
. Circuit K24 from the engine speed sensor provides
ertrain Control Module (PCM). Circuit T13 connects
an input signal to the PCM. The K24 circuit connects
to cavity B25 of the PCM. Circuit T14 connects to
to cavity A8 of the PCM connector.
cavity B28.
The PCM provides a ground for the engine speed
sensor signal (circuit K24) through circuit K4. Circuit
WATER-IN-FUEL SENSOR—DIESEL ENGINE * -
K4 connects to cavity A4 of the PCM connector.
The water-in-fuel sensor provides an input to the
Powertrain Control Module (PCM) on circuit K l . Cir HELPFUL INFORMATION '
cuit K l connects to cavity A27 of the PCM. Circuit K 4 splices to supply ground for the signals
From circuit. K l , ' the water-in-fuel sensor draws from the following:
voltage from the PCM. The sensor is a variable resis . • Throttle position sensor
tor. As the amount. of water in the fuel separator • Water-in-fuel sensor
changes, the resistance in the sensor changes, caus • Vehicle speed sensor
ing a change in current draw. • Intake air temperature sensor
> The PCM provides a ground for the water-in-fuel
sensor signal. (circuit K l ) through circuit K4. Circuit FUEL HEATER RELAY—DIESEL ENGINE
K4 connects to cavity A4 of the PCM. When the ignition switch is in the START or RUN
position, it connects circuit A l from fuse 3 in the
HELPFUL INFORMATION . - . - .• -
PDC to circuit A21. Circuit A21 powers circuit F18
Circuit K4 splices to supply ground for signals
through fuse 9 in the fuse block. Circuit F18 supplies
from the following:
battery voltage to the coil side of the fuel heater
• Intake air temperature sensor
relay. Circuit Z12 provides ground for the coil side of
• Vehicle speed sensor
the relay.
• Battery temperature sensor
Circuit A12 from the Power Distribution Center
© Crankshaft position sensor
(PDC) supplies battery voltage to the contact side of
• Throttle position sensor
the fuel heater relay. When voltage is present on cir
cuit F18, the relay energizes and its contacts close to
INTAKE AIR TEMPERATURE SENSOR—DIESEL
connect circuits A12 and A93.
ENGINE Circuit A93 supplies power to the fuel heater. Cir
The intake air temperature sensor provides an cuit Z12 provides ground for the fuel heater.
input to the Powertrain Control Module (PCM) on
circuit K21. Circuit K21 connects to cavity A15 of the FUEL SHUT DOWN RELAY—DIESEL ENGINE
PCM. When the engine starter motor relay energizes, its
From circuit K21, the intake air temperature sen contacts close and connect circuit A2 from fuse 2 in
sor draws voltage from the PCM. The sensor is a the Power Distribution Center (PDC) to circuit T40.
variable resistor. As intake air temperature changes, Circuit T40 supplies battery voltage to the engine
starter motor solenoid and to the coil side of the fuel
8W - 3 0 - 8 8W - 30 FUEL/IGNITION SYSTEMS BR
shut down relay. Circuit Z12 provides ground for the EGR SOLENOID—DIESEL ENGINE
coil side of the relay. When the Automatic Shut Down (ASD) relay ener
Circuit A18 from the Power Distribution Center gizes, i t connects circuit A16 from fuse 4 in the
(PDC) supplies battery voltage to the contact side of Power Distribution Center (PDC) to circuit A142. Cir
the fuel shut down relay. When voltage is present on cuit A142 powers the EGR solenoid. The EGR control
circuit T40, the relay energizes and its contacts close module provides' ground for the solenoid on circuit
to connect circuits A18 and A123. Circuit A123 sup K35.
plies power to one of the two coils in the fuel shut
down solenoid. EGR INTAKE AIR TEMPERATURE S E N S O R -
When circuit A123 energizes, the fuel shut down DIESEL ENGINE
solenoid raises the injection pump shut down lever to The EGR intake air temperature sensor provides
the RUN position. an input to the EGR Control Module (PCM) on cir
When the ignition switch is released to the RUN cuit K321. Circuit K321 connects to cavity 4 of the
position, i t connects circuit A l from fuse 3 in the EGR control module.
PDC to circuit A21. Circuit A21 powers circuit F18 From circuit K321, the intake air temperature sen
through fuse 9 in the fuse block. Circuit F18 supplies sor draws voltage from the EGR control module. The
battery voltage to the second coil in the fuel shut sensor is a variable resistor. As intake air tempera
down lever. When Circuit F18 energizes, the fuel ture changes, the resistance i n the sensor changes,
shut down solenoid holds the injection pump shut causing a change in current draw.
down lever in the RUN position. The PCM provides a ground for the intake air tem
Circuit Z12 provides ground for the fuel shut down perature sensor signal through circuit K204. Circuit
solenoid. Refer to Group 14, Fuel Systems, for fuel K204 connects to cavity 5 of the EGR control module.
shut down solenoid operation.
EGR ENGINE COOLANT TEMPERATURE S E N S O R -
INTAKE MANIFOLD AIR HEATER RELAYS—DIESEL
DIESEL ENGINE
ENGINE The EGR engine coolant temperature sensor pro
When the ignition switch is in the START or RUN vides an input to the EGR control module on circuit
position, i t connects circuit A l from fuse 3 in the K2.
PDC to circuit A21. Circuit A21 powers circuit F18 From circuit K2, the sensor draws voltage from the
through fuse 9 in the fuse block. Circuit F18 supplies EGR control module. The sensor is a variable resis
battery voltage to the coil side of each intake mani tor. As coolant temperature changes, the resistance
fold air heater relay. in the sensor changes, causing a change in current
The Powertrain Control Module (PCM) provides draw.
ground for the coil in each relay on separate circuits. The EGR control module provides ground for the
The PCM grounds first relay on circuit S21; i t sensor signal (circuit K2) on circuit K304.
grounds the second relay on circuit S22.
When the first intake manifold air heater relay
energizes, its contacts close and connect circuit A19 SCHEMATICS A N D DIAGRAMS
from the left battery positive terminal to circuit A58.
Circuit A58 connects to the intake air heater. WIRING DIAGRAM INDEX
When the second intake manifold air heater relay This section of the wiring diagrams has separate
energizes,' its contacts close and connect circuit A8 indexes for gasoline engines and diesel engines. I f
from the left battery positive terminal to circuit the component you are looking for is not found here,
A122. Circuit A122 connects to the intake air heater. refer to section 8W-02 for a complete list of all com
The intake manifold air heaters are case grounded. ponents shown in the wiring diagrams.
Refer to Group 14, Fuel Systems, for intake manifold
heater Pre-Heat and Post-Heat Cycles.
Bm • — - 8W-30 FUEL/IGNITION SYSTEMS 8W - 30 - 9
(WITH GAS ENG)
COMPONENT INDEX
A/C High Pressure Cutout Switch 8W-30-15 Fuse 15 8W-31M7
A/C Low Pressure Cutout Switch 8W-30-15 Fuse 16 8W-30-11
Airbag Control Module 8W-30-13 F2 8W-30-11
Automatic Shutdown Relay 8W-30-12 Generator 8W-30-28
Battery Temperature Sensor 8W-30-24 Heated Oxygen Sensors 8W-30-29, 32, 33, 37, 38
Camshaft Position Sensor 8W-30-22 Idle Air Control Motor 8W-30-26
Circuit Breaker 1 8W-30-11 Ignition Coil 8W-30-28
Controller Anti-Lock Brake 8W-30-13,16 Ignition Coil 4-Pack (8.0L ENG) 8W-30-36
Crankshaft Position Sensor 8W-30-27 Ignition Coil 6-Pack (8.0L ENG) 8W-30-36
Data Link Connector 8W-30-13 Ignition Switch 8W-30-11,12, 20
Duty Cycle Evap/Purge Solenoid 8W-30-20 Injectors (3.9L ENG) 8W-30-30, 31
Engine Coolant Temperature Sensor 8W-30-26 Injectors (5.2L/5.9L ENG) 8W-30--34, 35
Exhaust Gas Recirculation Solenoid 8W-30-20 Injectors (8.0L ENG) 8W-30-39, 40
Fuel Pump Module 8W-30-21 Instrument Cluster 8W-30-16,17,19, 21
Fuel Pump Relay 8W-30-20 Intake Air Temperature Sensor 8W-30-23
Fuse 2 (PDC) 8W-30-11 Joint Connector B 8W-30-13
Fuse 3 (PDC) 8W-30-11,12, 20 Joint Connector C 8W-30-11,16, 25
Fuse4(PDC) 8W-30-12 Manifold Absolute Pressure 8W-30-23
Fuse 5 8W-30-11 Message Center 8W-30-17
Fuse 6 8W-30-11 Overdrive Switch 8W-30-19
Fuse 7 8W-30-11 Powertrain Control Module 8W-30-12 thru 40
Fuse 8 8W-30-11 Throttle Position Sensor 8W-30-24
Fuse 8 (PDC) 8W-30-20, 25 Transmission Output Shaft Speed Sensor 8W-30-18
Fuse 9 8W-30-11,12, 20 Transmission Solenoid Assembly 8W-30-14,19
Fuse 11 8W-30-11 Vehicle Speed Control Servo 8W-30-25
Fuse 12 8W-30-11 Vehicle Speed Control/Horn Switch 8W-30-18
Fuse 14 8W-30-11 Vehicle Speed Sensor 8W-30-14
8040d003 J968W-9
8W-30-10 8W-30 FUEL/IGNITION SYSTEMS BR
(WITH DIESEL ENG)
COMPONENT INDEX
A/C High Pressure Cutout Switch 8W-30-15 Fuse 9 . . . 8W-30-11,12,41
A/C Low Pressure Cutout Switch 8W-30-15 Fuse 11 8W-30-11
Airbag Control Module 8W-30-13 Fuse 12 8W-30-11
Automatic Shut Down Relay 8W-30-12 Fuse 14 8W-30-11
Battery Temperature Sensor 8W-30-45 Fuse 15 8W-30-11
Controller Anti-Lock Brake 8W-30-13,16 F2 8W-30-11
Data Link Connector 8W-30-13 Generator 8W-30-45
EGR Control Module 8W-30-49 Heated Intake Air System 8W-30-48
EGR Engine Coolant Temperature Sensor 8W-30-49 Heated Intake Air System Relay 1 8W-30-48
EGR Intake Air Temperature Sensor 8W-30-49 Heated Intake Air System Relay 2 8W-30-48
Engine Speed Sensor 8W-30-46 Ignition Switch 8W-30-11,12,41
Exhaust Gas Recirculation Solenoid 8W-30-49 Instrument Cluster 8W-30-17 ,19,42,48
Fuel Heater 8W-30-47 Intake Air Temperature Sensor 8W-30-44
Fuel Heater Relay • • • • 8W-30-47 Joint Connector B. 8W-30-13
Fuel Pump Module 8W-30-42 Joint Connector C 8W-30-11,16,43
Fuel Pump Relay 8W-30-41 Message Center 8W-30-17.45
Fuel Shut Down Relay 8W-30-47 Overdrive Switch. 8W-30-19
Fuel Shut Down Solenoid 8W-30-47 Powertrain Control Module
Fuse 2 (PDC) 8W-30-11 8W-30-12 thru 19, 41 thru 46,48, 49
Fuse 3 (PDC) 8W-30-11,12,41 Throttle Position Sensor 8W-30-44
Fuse 4 (PDC) 8W-30-12 Transmission Output Shaft Speed Sensor 8W-30-18
Fuse 5 8W-30-11 Transmission Solenoid Assembly 8W-30-14,19
Fuse 6 . 8W-30-11 Vehicle Speed Control Servo 8W-30-43
Fuse 7 8W-30-11 Vehicle Speed Control/Horn Switch 8W-30-18
Fuse 8 8W-30-11 Vehicle Speed Sensor 8W-30-14
Fuse 8 (PDC) 8W-30-41.43 Water-ln-Fuel Sensor 8W-30-44
8040d005 J968W-9
1
BR 8W-30 FUEL/IGNITION SYSTEMS
bAiTERY -AO 6RD-

8W-30-11
POSITIVE
TERMINAL
<8W-20-3,4)
RIGHT
BATTERY
POSITIVE
1
TERMINAL
(8W-20-4)
RED
BRAKE
WARNING
LAMP
DRIVER
A41 A41
18Db 18DB
YL YL
I
f f
BYPASS CLUTCH
JUMPER PEDAL
(8W-21-3.4) POSITION
SWITCH
(8M-21-3,4)
FUSE
(39) C241 BLOCK
FUSE S FUSE S FUSE

* WITH GAS ENG
15A \ 15A 1 20A ** WITH D I E S E L ENG
8040d007 J968W-9
8W-30-12 8W-30 FUEL/iGllTIOl SYSTEMS BR
POWER
BATTERY
POSITIVE
TERMINAL
(8W-20-3,4)
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH
D I E S E L ENG)
(8W-20-4)
TRANSMISSION
RELAY
C8W-31-4)
(8W-11-9)
* WITH GAS ENG

8040d009 J968W-9
BR- 8W-30 FUEL/IGNITION SYSTEMS- 8W - 30 - 1 3
* WITH GAS ENG

8040d00c J968W-9
8W-30-14 8W-30 FUEL/IGNITION SYSTEMS- BR
G7
20WT
OR
C127
G7
22WT
WITH OR
DIESEL
ENG
C133
G7
20WT
OR
S210
!8W-70-31
G7
20WT
OR
INSTRUMENT
CLUSTER
(8W-40-5)
POWERTRAIN
A4 B31 B29 B27
SENSOR 5 VOLT CONTROL
GOV PRESS VEHICLE
GND SUPPLY SIG SPEED MODULE
SENSOR
SIGNAL
8040d00f J968W-9
BR 3W-30 FUEL/IGNITION SYSTEMS 8W-30-15
C90 18LG/WT
A/C
(2): C182 C16S COMPRESSOR
A / C LOW A / C HIGH A/C-HEATER CLUTCH
PRESSURE PRESSURE CONTROL RELAY
CUTOUT CUTOUT SWITCH (8W-42-8)
SWITCH SWITCH (8W-42-6) (8W-11-8)
C90
(1): C182
22LG
C133
C13
C90 22DB
18LG OR
C12S
C90
S160 18LG
8W-70-26
C20
18BR C12S
C90 C13
18LG 20DB
OR
C137
POWERTRAIN
C22 C23 CI CONTROL
A/C A/C A/C MODULE
REQUEST SELECT CMP
INPUT CLUTCH
RLY
CTRL
. — J
8040d010 J968W-9
8W-30-16 8W-3Q FUEL/IGNITION SYSTEMS BR
JOINT CONTROLLER "1 I N S T R U M E N T

CONNECTOR C ANTI-LOCK CLUSTER
BRAKE
BRAKE
SW UPSHIFT
SENSE LAMP
9 DRIVER
C121 (3): C216
G54
220R
BK
(NOT USED)
C22S
C133
T18
22LG
OR
C12S
G54
200R
BK
C136
POWERTRAIN
Bll
CONTROL
UPSHIFT
LAMP NODULE
DRIVER (WITH MAN TRANS)
(EXCEPT HEAVY DUTY)
(EXCEPT DIESEL ENG
AND 8 . 0 L ENG)
8040d012 J968W-9
BR 8W-30 FUEL/IGNITION SYSTEMS 8W-30-17
MESSAGE INSTRUMENT
CENTER CLUSTER
iWATER-IN- TRANS J
| FUEL TEMP »
i WARNING SRI LAMP ! ! GEN
J LAMP LAMP DRV i i LAMP MIL TACH J
i DRIVER DRIVER (AUTO ! J DRV DRIVER SIGNAL i
1 (DIESEL) (GAS) TRANS) '
j
(5)^ (6) ^
. __
(3) $£ C 2 1 5
j
(2)^ (7) J (8)^ £ C224
G86 G24 G14 G12 G3 G21

20TN 22GY 20PK 22TN 22BK 22GY
OR PK BK YL PK LB
C133 C133
G86 G24 G14 G12 G3 G21

OR PK BK YL PK LB
C125 C126 CI 25 C125 C126 C127
G86 G24 G14 G12 G3 G21

OR PK BK YL PK LB
s^ C137 . 2 K C137 ' $ S C137

r
POWERTRAIN
i C18 C18 C7 C16 C17 C31 CONTROL
! WATER SRI TRANS GEN MIL TACH
MODULE
- I N- LAMP TEMP LAMP DRIVER SIGNAL
j FUEL DRIVER LAMP DRIVER
! WARNING (GAS) DRIVER
» LAMP (AUTO
1 DRIVER TRANS)
| (DIESEL)
8040d014 J968W-9
8W-30-18- 3W-30 FUEL/IGNITION SYSTEMS- 'BR
S156
8W-70-24
•K4 20BK/LB«
C133
K4
20BK
LB
K4
i C12S 18BK
LB
K4
T
20BK
LB (3): C203
SENSOR VEHICLE
GND SPEED
CONTROL/
HORN
SC SWITCH
Si TRANSMISSION
WITH K4 RELAY
DIESEL- 20BK • SIGNAL
ENG (8W-31-4)
LB
(8W-11-9)
K4
20BK
S1S4
8W-70-23
(4)X
T
V37
C203
LB 22RD
K4 LG
18BK
LB TRANSMISSION
OUTPUT K30
S1S7 S129 C133 OUTPUT OUTPUT 20PK
SHAFT
8W-70-25 8W-70-12 SHAFT SHAFT SPEED
SPD SPD SENSOR
V37 SENSOR SENSOR (WITH AUTO
K4 K4 GND SIGNAL
20BK 20BK 20RD TRANS)
LB LB LG
(2): (1): C187
C12S
C126
T13 T14
¥37 18DB 18LG K30
K4 20RD BK BK 20PK
20BK LG
LB
C13S C137 C136 C13e

POWERTRAIN
A4 C32 B25 B28 B30
SENSOR SC OUTPUT OUTPUT TRANSMISSION CONTROL
GND SW . SHAFT SHAFT • RELAY ~ MODULE
SIGNAL SPD SPD CONTROL
SENSOR SENSOR
GND SIGNAL
8040d015 J968W-9
BR 8W-30 FUEL/IGNITION SYSTEMS 8W-3Q-19
NOT FUNCTIONAL
(5) C225 WITH AUTO TRANS
OD
OVERDRIVE
LAMP SWITCH
T18 G54
DRIVER
22LG 220R
OR BK
TRANS
OD
SW
SENSE
TRANSMISSION SOLENOID ASSEMBLY (3) C216
(1) : C225 UPSHIFT
! INSTRUMENT
LAMP
CLUSTER
>f C133
DRIVER
T6
i VARIABLE TRANS | 220R
| FORCE OD TCC TEMP i WT
i SOL SOL SOL SENSOR |
| CONTROL CONTROL CONTROL SIG i
(5): (6): 7)i (8): C167

T18
22LG C133
OR
T6
220R
WT
K88 T60 K54 T54 C125

20VT 20BR 200R 18VT
WT BK
C125
T18
20LG
OR 16
200R
WT
C136 C137
POWERTRAIN
B8 B21 Bll Bl C6 C13 CONTROL
VARIABLE OD TCC TRANS OD TRANS
FORCE SOL SOL TEMP LAMP OD SW MODULE
SOL CONTROL CONTROL SENSOR DRIVER SENSE
CONTROL SIG
8040d017 J968W-9
8W --30 -20- 8W-30.FUEL/IGNITION SYSTEMS-
• (WITH I A S E l l )
SPLICE
•AO 20BK S148
(8W-70-21) ENGINE
STARTER
•AO 6RD —
MOTOR
BATTERY POWER (8W-21-3)
POSITIVE DISTRIBUTION
C180 CENTER
TERMINAL
(8W-20-3)
A14
16RD
WT
C127
AUTOMATIC A14
16RD
S H U T DOWN
WT
RELAY
C8W-30-12)
(8W-11-10)
F18
20LG A14
BK 16RD
F18
WT
20LG TRANSMISSION
BK RELAY
(8W-31-4)
C8W-11-9)
TRANSMISSION
RELAY
(8W-31-4) A14 POWER
C8W-11-9) 16RD/WT DISTRIBUTION
CENTER
18LG/BK
I (86) : (30) C180
S132
•• FUEL
F18 PUMP
8W-70-13 20LG/BK RELAY
DUTY EXHAUST (85) (87): C180

CYCLE GAS
EVAP/ RECIR
PURGE CULATION
K31 A61
SOLENOID SOLENOID
20BR 16DG FUEL
(WITH
WT BK PUMP
5 . 2 L AND
MODULE
C146 5.9L
Y ^ C127 C8W-30-21)
ENG)
F18 K35 K31 C129
K52
20LG 20GY 20BR
20PK
BK YL WT L-A61 16DG/BK
^ C137
I^ C135 ^ C138 4^ C137 C135
POWERTRAIN
•
j
C20
EVAP
A2
FUSED
B32
EGR
C19
FUEL A22
FUSED' 1 CONTROL
MODULE
1 SOL IGN SW SOL PUMP B(+) j
i CONTROL INPUT CONTROL RLY
(START/RUN) CONTROL
8040d019 J968W-9
tot 8W-30 FUEL/IGNITION.SYSTEMS- 8W - 30 • 21
(WITH GAS E1G)
INSTRUMENT
FUEL CLUSTER
PUMP
RELAY
(8W-30-20)
(8W-11-11)
WITH
TRAILER
TOW
8040d01b J968W-9
8W-3Q FUEL/IGNITION SYSTEMS
(WITH GAS E1G)
CAMSHAFT
POSITION
SENSOR
( I N DISTRIBUTOR
WITH 3 . 9 L , 5 . 2 L
AND 5 . 9 L ENG)
(1) : (3) : (2) C171
K6 K4
20VT 20BK
WT LB
S136
8W-70-16
K4
18BK
LB
S137 K44
S154
8W-70-17 20TN 8W-70-23
YL
K4
18BK
LB
S129
8W-70-12
K6 K4
20VT 20BK
WT LB
C135
POWERTRAIN
A17 A18 A4
CONTROL
5 VOLT CMP SENSOR
SUPPLY SENSOR GND MODULE
SIGNAL
BR- 8W-30 FUEL/IGNITION SYSTEMS 8W - 30 - 23
(WITH GAS ENG)
INTAKE
All
TEMPERATURE
SENSOR
C157
K4
18BK
LB
WITH
3.9L.5.2L. WITH
AND 5.9L 8.0L ENG
ENG
K4
18BK
LG
K4 S136
18BK 8W-70-16
LG
K21 K4
18BK 18BK
RD LB
S129 S154
I8W-70-12I 8W-70-23
K4
18BK
LB
K4 S129
20BK 8W-70-12
LB
K4
20BK
LB
K4
20BK
LB
C13S
POWERTRAIN POWERTRAIN
A15 A4 . CONTROL A17 A27 A4 • CONTROL
I AT SENSOR 5 VOLT MAP SENSOR
SIGNAL GND MODULE SUPPLY SENSOR GND MODULE
SIGNAL
* WITH 8.0L ENG

** WITH 3.9L, 5.2L AND 5.9L ENG
J968W-9
8W - 30 - 24 8W-30 FUEL/IGNITION SYSTEMS
(WITH GAS E I G )
THROTTLE
POWERTRAIN
C15 A4 A17 A23 CONTROL
BATTERY SENSOR 5 VOLT TP
TEMP GND MODULE
SUPPLY SENSOR
SENSOR SIGNAL
SIGNAL
8040d021 J968W-9
urn 8W-30 FUEL/IGNITION SYSTEMS- 8W - 30 - 25
(WITH GAS ENG)
POWER
DISTRIBUTION
BATTERY C180 CENTER
POSITIVE i I FUSE 8
AO 6RD-
TERMINAL
(8)
(8W-20-3)
A14
16RD
ENGINE WT
F U E L PUMP
STARTER TRANSMISSION
A14 RELAY
MOTOR SPLICE RELAY -16RD- C8W-30-20)
C8W-21-3) S148 (8W-31-4) WT (8W-11-11)
(8W-70-21) (8W-11-9)
G119
8W-15-11
VEHICLE
S P E E D CONTROL
SERVO
SC SC (WITH SPEED
VACUUM VENT CONTROL, H I G H -
SOL SOL LINE CLUSTER)
CONTROL CONTROL
(1) : (2): C109

JOINT
V36 V35
20TN 20LG
RD RD
WITH
SPEED CONTROL
HIGH-LINE
CLUSTER
C133
C126
V32
20YL
RD
V36 V35
20TN 20LG C126
RD RD
V32
20YL
RD
C137 C135
POWERTRAIN
C4 C5 Cll A31 A3 2 A22 CONTROL
sc • SC SC GND GND FUSED
MODULE
VACUUM VENT FEED B(+)
SOL SOL
CONTROL CONTROL
8040d022 J968W-9
30-26- 8W-30 FUEL/IGNITION SYSTEMS BR
(WITH GAS ENG)
1 I D L E AIR
CONTROL
MOTOR
I AC I AC I AC I AC
MOTOR MOTOR MOTOR MOTOR
NO. 1 NO. 2 NO. 3 NO. 4
DRIVER DRIVER DRIVER DRIVER
(1): (2): (3): (4): C150
C152
ENGINE
K39 K60 K40 K59 K4 COOLANT
18GY 18YL 18BR 18VT 18BK TEMPERATURE
RD BK WT BK LB ' SENSOR
C152
S129
1 8W-70-12
K4 K2
20BK 18TN
LB BK
C13S
1 POWERTRAIN
A19 AlO All A20 A4 A16
I AC I AC I AC I AC SENSOR CONTROL
ECT
MOTOR MOTOR MOTOR MOTOR GND SENSOR MODULE
NO. 1 NO. 2 NO. 3 NO. 4 SIGNAL
J968W-9
BR 8W-30 FUEL/IGNITION SYSTEMS 8W - 30 - 27
(WITH GAS ENG)
CRANKSHAFT
POSITION
SENSOR
(l) ^ (3) si: (2) C13S

ENGINE S T A R T E R
MOTOR R E L A Y
(8W-21-3)
(8W-11-17)
K6 T41
20VT 22BK
WT WT
K4
18BK C125
WITH LB
8.0L
ENG S136
8W-70-16
K4 K4
20BK 18BK
LB LB WITH
i MAN
Z12 TRANS
S137 K24 $129 $154 T41 20BK
8W-70-17 20GY 8W-70-12 8W-70-23 20BK TN
BK WT
I S151
8W-70-22
K4 K4
20BK 18BK
LB LB Z12
10BK
S129 S141
TN
O 8W-70-12 8W-70-19
y | S150
I • [8W-70-22
K4 T41
20BK 18BK
LB WT
K6 Z12
20VT 14BK
WT f T41 TN
20BK
PARK/
WT
NEUTRAL G119
K4 POSITION 8W-15-11
20BK SWITCH
LB (8W-21-3)
C135
POWERTRAIN
A17 A8 A4 A6
CONTROL
5 VOLT CKP SENSOR PNP
SUPPLY SENSOR GND SWITCH MODULE
SIGNAL SENSE
8040d026 J968W-9
8W - 30 - 28 8W-30 FUEL/IGNITION SYSTEMS BR
(WITH GAS E I G )
C127
AUTOMATIC
• A142 14DG/0R
SHUT DOWN
RELAY
(8W-30-12) A142
C8W-11-10) 14DG
OR
S138
I8W-70-17]
A142
14DG
OR
S135
• A142 14DG/0R- 8W-70-15
A142
14DB
(2) : C 1 5 1
GENERATOR
ASD
(2): C170 RELAY
IGNITION COIL OUTPUT
(WITH 3.9L. 5.2L
AND 5.9L ENG) GENERATOR
FIELD
DRIVER
C170 (1): C151
K20
18DG
S134
8W-70-14
K20
18DG
C135 C136
A7 POWERTRAIN
BIO
IGN COIL GENERATOR CONTROL
NO. 1 FIELD MODULE
DRIVER DRIVER
. J
8040d027 J968W-9
8W-30 FUEL/IGNiTiON SYSTE1S- 8W - 30 - 2S
(3 J L ENGINE)
AUTOMATIC
S H U T DOWN C127
RELAY • A142 14DG/0R
(8W-30-12)
(8W-X1-10)
UPSTREAM
HEATED
OXYGEN
i A25 A4 ! A24 A4
CONTROL CONTROL
! DOWNSTREAM SENSOR i UPSTREAM SENSOR
MODULE MODULE
« HEATED GND | HEATED GND
| OXYGEN OXYGEN
i SENSOR SENSOR
| SIGNAL SIGNAL
8040d029 J968W-9
8W-30-30- 8W-30 FUEL/IGNITION SYSTEMS
(3.9L ENGINE)
AUTOMATIC
S H U T DOWN
IELAY i • A142 14DG/0R
(8W-30-12)
CSW-11-10)
8040d02b J968W-9
8W-30' FUEL/iiilTlOl'SYSTEMS 8W - 3 0 - 3 1
(3Ml ENGINE)
AUTONATIC
S H U T DOWN C127
RELAY i •A142 14DG/0R
(8W-30-12)
(8W-1I-10)
C142
INJECTOR
NOo §
POWERTRAIN
B15 B16 B12 CONTROL
INJ INJ INJ
MODULE
NO. 2 NO. 4 NO. 6
DRIVER DRIVER DRIVER
8040d02e J968W:-9
8W-30-32- 8W-30 FUEL/IGNITION SYSTEMS
(5.2L/5.9L ENGINES EXCEPT HEAVY DUTY TRANS)
AUTOMATIC
SHUT DOWN C127
RELAY
(8W-30-12)
(8W-11-10)
C162
A142 16DG/OR ^f-

(1
UPSTREAM
Zll 18BK/WT
POWERTRAIN
i A25 A4 [ A24 A4
| DOWNSTREAM SENSOR i
CONTROL UPSTREAM SENSOR
CONTROL
« HEATED GND [ MODULE MODULE
HEATED GND
J OXYGEN OXYGEN
i SENSOR SENSOR
i SIGNAL SIGNAL
8040d02f J968W-9
BR- 8W-30 FUEL/IGNITION SYSTEMS- 8W - 3 0 - 3 3
(5.9L ENGINE HEAVY DUTY TRANS ONLY)
AUTOMATIC
S H U T DOMN C127
RELAY • A142 14DG/0R- ((
(8W-30-12)
C8W-11-I0)
A142 16DG/OR
Zll 18BK/WT
C135
A4 A24
SENSOR UPSTREAM
GND HEATED
OXYGEN
SENSOR
SIGNAL
8040d032 J968W-9
IW - 31 - 34 8W-30 FUEL/IGNITION SYSTEMS BM
(5.2L/5.9L ENGINES)
AUTOMATIC
SHUT DOWN C127
RELAY i •A142 14DG/0R-
C8W-30-12)
(8W°11-10)
A142
14DG
OR
S138
8W-70-17
A142
14DG
OR
S133
8W-70-14
A142 A142 A142 A142

16DG 16DG 16DG 16DG
OR OR OR OR
(2) C159 (2) : C158 (2): C156 C155

INJECTOR INJECTOR INJECTOR INJECTOR
NO. 1 NO. 5 NO. 7
(1): C159 (1): C158 (1): C156 C155
Kll K13 K38

18WT 18YL 18GY
DB WT
C136
POWERTRAIN
B4 B5 B6 B2 CONTROL
INJ INJ INJ INJ MODULE
NO. 1 NO. 3 NO. 5 NO. 7
8040d034 J968W-9
(5.2L/5.9L ENGINES)
AUTOMATIC
SHUT DOWN C127
RELAY • A142 14DG/0R-
(8W-30-12)
(8W-11-10)
A142
14DG
OR
_ S3L38
(8W-7G 17
B15 B16 B12 B13 CONTROL

INJ INJ INJ INJ
NO. 2 NO. 4 NO. 6 NO. 8 MODULE
8040d036 J968W-9
(8.0L ENGINE)
AUTOMATIC
SHUT DOWN €12?
RELAY A142 14DG/0R (f—
(8W-30-12)
(8W-11-10)
A142
14DG
OR
$138
[8W-70-17I
A142
14DG
OR
S135
8W-70-15
A142 A142
14DG 14DG
OR OR
(2)2 ^ C141 (3) C144

! ASD
IGNITION
ASD
IGNITION
i RLY
COIL RLY
COIL
! OUTPUT 4-PACK OUTPUT 6-PACK
! IGN C O I L IGN C O I L IGN C O I L IGN C O I L IGN C O I L

j NO. 2 NO. 3 NO. 1 NO. 4 NO. 5
» DRIVER DRIVER DRIVER DRIVER DRIVER
_i k _ (3_)jJ £ C141 (1) (2): (4): C144
K17 K18 K19 K32 K43

18DB 18RD 18BK 18YL 18DG
WT BK GY GY GY
C135
A9 A3 A7 Al A5 POWERTRAIN
IGN C O I L IGN C O I L IGN C O I L IGN C O I L IGN C O I L CONTROL
NO. 2 NO. 3 NO. 1 NO. 4 NO. 5 MODULE
DRIVER DRIVER DRIVER DRIVER DRIVER
8040d03a J968W-9
BR® 8W-30 FUEL/IGNITION SYSTEMS- 8W • 30 • 37
- (8.0L ENGINE) '
AUTOMATIC
SHUT DOWN C12?
RELAY •A142 14DG/0R <(
(8W-30-12)
(8W-I1-10)
8040d03c J968W-9
8W-30-S8 • 8W-38 FUEL/IGNITION SYSTEMS - BR
(8.0L ENGINE-CALIFORNIA ONLY)
AUTOMATIC
SHUT DOWN C127
RELAY •A142 14DG/0R «-
(8W-30-I2)
(8W-11-IO)
A29 A4
PRE-CATALYST SENSOR
HEATED GND
OXYGEN
SENSOR
SIGNAL
8040d03e J968W-9
BR' 8W-30 FUEL/IGNITION SYSTEMS 8W - 30 - 31
(8 J L ENGINE)
AUTOMATIC
SHUT D O W N €127
RELAY i •A142 14DG/0R- -<f-
(8W-30-12)
(8W-11-10)
A142
14DG
OR
$138
8W-70-17
8040d040 J968W-9
(8.01 ENGINE)
AUTOMATIC
C127
SHUT DOWN
IELAY i • A142 14DG/0R-
C8W-30-12)
C8W-11-10)
A142
14DG
OR
S138
8W-70-17
A142
14DG
OR
S135
8W-70-15
A142 A142 A142 A142 A142

16DG 16DG 16DG 16DG 16DG
OR OR OR OR OR
POWERTRAIN
B15 B16 B12 B13 B14
CONTROL
INJ INJ INJ INJ INJ
MODULE
NO. 2 NO. 4 NO. 6 NO. 8 NO. 10
DRIVER DRIVER DRIVER DRIVER DRIVER
8040d042 J968W-9
(WITH DIESEL ENG)
SPLICE S 1 4 8
-AO 14PK ENGINE
(8W-70-21)
STARTER
-AO OOERD- — MOTOR
POWER (8W-21-4)
LEFT
BATTERY
POSITIVE
TERMINAL
(8W-20-4)
RIGHT
BATTERY
POSITIVE
TERMINAL
(8W-20-4)
AUTOMATIC
S H U T DOWN
RELAY
(8W-30-12)
(8W-11-10)
C127
F18
20LG
BK
F18
20LG
BK TRANSMISSION RELAY
$114 (8W-31-4) A14
8W-70-7 (8W-11-9) 16RD
•F18 2 0 L G / B K - WT
A14 POWER
16RD/WT DISTRIBUTION
CENTER
TRANSMISSION
RELAY F18
18LG (86) : (30) C180
(8W-31-4)
BK FUEL
(8W-11-9) NOT NOT
FUNCTIONAL FUNCTIONAL PUMP
ON DIESEL ON DIESEL RELAY!
C126 (NOT (NOT
NOT NOT USED USED
FUNCTIONAL FUNCTIONAL ON ON
F18 ON DIESEL ON DIESEL DIESEL) DIESEL)!
18LG
BK ClfO
S132 NOT
K31
20BR FUNCTIONAL
8W-70-13
WT ON DIESEL
FUEL
F18 C127 PUMP
18LG MODULE
K31
BK C8W-30-42)
20BR
WT
C135
C19
^ C137
A61 16DG/BK
j A22
C135
POWERTRAIN
A2
CONTROL
FUSED NOT FUSED
FUNCTIONAL B(+) MODULE
IGN SW
INPUT ON
(START/RUN) DIESEL
8040d044 J968W-9
8W-30-42- 8W-30 FUEL/IGNITION SYSTEMS- BR
(WITH DIESEL ENG)
FUEL
PUMP
I E LAY
(8W-30-41)
(8W-11-11)
C133 INSTRUMENT
G4 20DB- •G4 22DB
NOT
FUNCTIONAL
ON C128
DIESEL C128
—« K4 20BK/LB"
G4
20DB S156
K4
OR
20BK
i8W-70-24
LB
K4
(3): (5) C328 20BK
NOT NOT FUEL LB
FUNCTIONAL FUNCTIONAL PUMP
ON D I E S E L ON D I E S E L MODULE
FUEL
LEVEL
NOT SENSOR NOT
FUNCTIONAL FUNCTIONAL C125
ON D I E S E L ON D I E S E L
(6)^______ (4): (2): C328

K4
Z13 - Zll 20BK
16BK 20BK K104 LB
WT 20DB
S311 WT
8W-70-37
C128
Zll C128
20BK
S157
WITH WT 8W-70-25
TRAILER-
TOW S116 K226
Z13 Z13 8W-70-8 20DB
16BK 12BK WT
Zll
C128 C128 16BK
WT K4
C126 20BK
Z13 Z13
LB
12BK 16BK
C127
K226
Zll 20DB
16BK WT
WT
S115
8W-70-8 S140
8W-70-18
€137 C135
Zl Zll i C26 A4 ! POWERTRAIN
12BK 16BK j NOT SENSOR i CONTROL
WT iFUNCTIONAL GND | MODULE
tits ! ON D I E S E L
G119
# 8W-15-6.7.8 • 8W-15-12
8040d046 J968W-9
BR 8W-30 FUEL/IGNITION SYSTEMS SW - 30 - 43
(WITH DIESEL ENG)
POWER
LEFT
BATTERY
POSITIVE
TERMINAL
(8W-20-4)
A14
16RD
RIGHT WT
BATTERY FUEL PUMP
POSITIVE ENGINE TRANSMISSION A14 RELAY
TERMINAL SPLICE STARTER RELAY ^ 16RD C8W-30-41)
(8W-20-4) S148 MOTOR (8W-31-4) WT C8W-11-11)
(8W-70-21) C8W-21-4) (8W-11-9) A14
16RD
WT
G119
8W-15-12
VEHICLE 111
14BK
SPEED CONTROL TN
SERVO
SC SC (WITH SPEED
VACUUM VENT CONTROL, HIGH-
SOL SOL LINE CLUSTER)
CONTROL CONTROL C127
(1): (2) C109 S142
JOINT 8W-70-19
CONNECTOR C
V36 V35
20TN 20LG
RD RD
WITH SPEED
CONTROL,
HIGH-LINE
CLUSTER
C126
V32
20YL
RD
V36 V35
20TN 20LG C126
RD RD
V32
20YL
RD
C137
POWERTRAIN
C4 C5 Cll A31 A3 2 A22
CONTROL
SC SC SC GND GND FUSED
VACUUM VENT FEED B( + )
MODULE
SOL SOL
CONTROL CONTROL
8040d047 J968W-9
8W-30-44- 8W-30 FUEL/IGNITION SYSTEMS L3B
(WITH DIESEL ENG)
Em
CONTROL THROTTLE
NODULE POSITION SENSOR
(WITH EGR
CAVITY 3 OR AUTO
C8W-30-49) TRANS)
C157
INTAKE A I R
TEMPERATURE
SENSOR
K4
20BK
LB
k C135
A15 A4 A27 A23 A17 POWERTRAIN
INTAKE SENSOR WATER TP 5 VOLT CONTROL
AIR GROUND -IN- SENSOR SUPPLY MODULE
TEMP FUEL SIGNAL
SENSOR SENSOR
SIGNAL SIGNAL
8040d049 J968W-9
BR 8W-30 FUEL/iGiiTiON SYSTEMS 8W - 30 - 45
(WITH DIESEL ENG)
AUTONATIC
S H U T DOWN C127
RELAY -A142 14DG/0R-
(8W-30-12)
(8W-11-10)
A142
14DG
OR
S143
BATTERY 8W-70-19
TEMPERATURE
A142
14DB
(2): C151
ASD GENERATOR
MESSAGE
RELAY CENTER
OUTPUT WAIT
-TO-
START
GENERATOR WARNING
FIELD LAMP
DRIVER DRIVER
(1): C151 (4): C224
G85
200R
BK
K20
18DG
C133
S134 G85
180R
8W-70-14 BK
C12S
K20
18DG G85
180R
BK
C136 C136
C15 A4 BIO B20 POWERTRAIN

BATTERY SENSOR GENERATOR WAIT CONTROL
TEMP GND FIELD -TO- MODULE
SENSOR DRIVER START
SIGNAL WARNING
LAMP
DRIVER
8040d04b J968W-9
1W - 31 - i e 3W-30 FUEL/IGNITION SYSTEMS
(WITH DIESEL ENG)
ENGINE
SPEED
SENSOR
ENGINE S T A R T E R
NOTOR R E L A Y
(8W-21-4)
(3): (2): (1): C138 (8W-11-17)
K6
20VT
WT T41
22BK
WT
C125
K4
20BK WITH MAN
LB TRANS
WITHOUT
EGR
K6
20VT WITH
WT ' MAN
Z12 TRANS
20BK
TN
T41
S1S7 K24
20GY
S137
K6
20BK
WT
I S152
8W-70-25 8W-70-17 20VT
BK 8W-70-22
WT
Z12
14BK
S141
TN
8W-70-19
K6
20VT y S142
8W-70-19
WT T41
18BK
K4 WT
T41
Z12
20BK 14BK
LB 20BK
TN
WT
PARK/
NEUTRAL G119
K6 POSITION
# |8W-15-12 |
20VT SWITCH
WT (8W-21-4)
4- C135
POWERTRAIN
A4 A8 A17 A6
SENSOR ENGINE 5 VOLT CONTROL
PNP
GND SPEED SUPPLY SWITCH NODULE
SENSOR SENSE
SIGNAL
8040d04d J968W-9
BE* • 8W-30 FUEL/IGNITION SYSTEMS 8W - 30 - 47
(WITH DIESEL ENG)
$152
8W-70-22
FUEL FUEL
HEATER $144 SHUT DOWN S145
FEED 8W-70-20 FEED 8W-70-20
(QjU A12 200R -I (Qg] A18 16DB (
A12 Z12 A18 Z12

14RD 20BK 10RD 18BK
TN TN BK TN
€172 €173
FUEL FUEL
HEATER SHUT DOWN
RELAY RELAY •
ENGINE
STARTER
€172 MOTOR
(8W-21-4)
T40
12BR
Z12 SPLICE
14BK $114 ^ C119
TN (8W-30-12)
(8W-70-7) T40
12BR
(1): €177 i
r FUEL
HEATER F18
18LG
BK ENGINE
^ C126 STARTER
(2): €177
'MOTOR
F18
RELAY
18LG (8W-21-4)
BK (8W-11-17)
Z12
16BK FUEL
TN
SHUT DOWN
$142 SOLENOID
8W-70-19
-F18 20LG/BK
$132
8W-70-13
Z12
14BK
TN
G119
8W-15-12
8040d04f J968W-9
8W-3Q-48* 8W-3Q FUEL/IGNITION SYSTEMS 6
BR
(WITH DIESEL ENG)
SPLICE
S114
(8W-30-12)
(8W-70-7)
BATTERY
POWERTRAIN
A7 A9 A2 C16 C17 C31
CONTROL
AIR AIR FUSED GEN MIL TACH
CASE CASE INTAKE INTAKE IGN SW LAMP DRIVER SIGNAL
MODULE
GROUND GROUND HEATER HEATER INPUT DRIVER
RELAY RELAY (START/RUN)
NO. 1 NO. 2
CONTROL CONTROL
8040d050 J968W-9
mm 8W-30 FUEL/IGNITION SYSTEMS 8W - 30 - 49
(DIESEL ENGINE-WITH EGR)
AUTOMATIC
SHUT DOWN lit
RELAY ENGINE COOLANT
(8W-30-I2)
C8W-11-10)
Z12 POWERTRAIN
14BK ; C9 A12 A17 A23
TN i EGR EGR 5 VOLT TP CONTROL
! DIAG FAULT SUPPLY SENSOR MODULE
G119 i * TEST MONITOR SIGNAL
8W-15-12 1 REQUEST
8040d052 J968W-9
8W - 31 TRANSMISSION CONTROLS 8W - 31 -1
8W-31 T R A N S M I S S I O N C O N T R O L S
INDEX
page page
DESCRIPTION AND OPERATION SPEED AUTOMATIC TRANSMISSION 1

ELECTRONIC TRANSMISSION RELAY—FOUR OVERDRIVE SWITCH 1
SPEED AUTOMATIC TRANSMISSION 1 TRANSMISSION SOLENOID A S S E M B L Y -
FOUR-WHEEL DRIVE INDICATOR 2 FOUR SPEED TRANSMISSIONS 1
GOVERNOR PRESSURE SENSOR—FOUR TRANSMISSION TEMPERATURE SENSOR 2
SPEED AUTOMATIC TRANSMISSION 1 SCHEMATICS AND DIAGRAMS
OUTPUT SHAFT SPEED SENSOR—FOUR WIRING DIAGRAM INDEX 2
DESCRIPTION A N D OPERATION cuit K30. Circuit K30 connects to cavity B30 of the
PCM.
OVERDRIVE SWITCH When the PCM grounds the relay, the relay con
Automatic transmission equipped vehicles may tacts connect circuit A14 from fuse 8 in the PDC to
have an overdrive switch. The operator disables or circuit T16. Circuit T16 powers the solenoids.
enables overdrive when the switch is depressed.
The overdrive system consists of a switch con OUTPUT SHAFT SPEED SENSOR—FOUR SPEED
nected to the Powertrain Control Module (PCM) and AUTOMATIC TRANSMISSION
an overdrive ON/OFF indicator lamp. The output shaft speed sensor generates a signal
I f overdrive is currently enabled, it is disabled indicating the speed of the transmission output shaft.
when the operator depresses the overdrive switch. Circuits T13 and T14 connect the sensor to the Pow
Also, if the operator already disabled overdrive, it is ertrain Control Module (PCM). Circuit T13 connects
enabled when the switch is depressed. to cavity B25 of the PCM. Circuit T14 connects to
Circuit T6 from the overdrive switch connects to cavity B28.
cavity C13 of the PCM and provides the overdrive
signal. Circuit Z l provides ground for the switch. TRANSMISSION SOLENOID ASSEMBLY—FOUR
In the START and RUN position, the ignition SPEED TRANSMISSIONS
switch connects circuit A l from fuse 3 in the Power The Torque Convertor Clutch (TCC) solenoid, over
Distribution Center (PDC) with circuit A21. Circuit drive solenoid and variable force solenoid are molded
A21 connects to the bus bar in the fuse block that together. They are only used on four-speed automatic
powers circuit F12 through fuse 11. Circuit F12 sup transmissions. Circuit T16 from the electronic trans
plies power for the overdrive ON/OFF indicator lamp. mission relay supplies power for the solenoids. The
The PCM turns the overdrive ON/OFF indicator Powertrain Control Module (PCM) operates each
lamp ON or OFF by providing a ground for the lamp solenoid individually by providing ground for each
on circuit T18. solenoid on separate circuits.
• The PCM provides ground for the TCC on circuit
ELECTRONIC TRANSMISSION RELAY—FOUR K54. Circuit K54 connects to cavity B l l of the PCM.
SPEED AUTOMATIC TRANSMISSION • The PCM supplies ground for the overdrive sole
The electronic transmission relay powers the over noid on circuit T60. Circuit T60 connects to cavity
drive solenoid, torque convertor clutch solenoid, and B21 of the PCM.
variable force solenoid. All three solenoids are • On circuit K88, the PCM provides ground for the
molded together. variable force solenoid. Circuit K88 connects to cavity
When the ignition switch is in the START or RUN B8 of the PCM.
positions, it connects circuit A l from fuse 3 in the
Power Distribution Center (PDC) to circuit A21. Cir I0WERN0R PRESSURE SENSOR—FOUR SPEED
cuit A21 powers circuit F18 through fuse 9 in the AUTOMATIC TRANSMISSION
fuse block. Circuit F18 powers the coil side of the The governor pressure sensor supplies the trans
electronic transmission relay. The Powertrain Control mission pressure input to the Powertrain Control
Module (PCM) provides ground for the relay on cir Module on circuit T25. Circuit T25 connects to cavity
B29 of the PCM. Circuit K7 from cavity B31 of the
8W - 31 - 2 8W - 31 TRANSMISSION CONTROLS BR
PCM supplies 5 volts to the sensor. The PCM pro • Heated oxygen sensors
vides ground for the govenor pressure sensor on cir • Crankshaft position sensor
cuit K4. Circuit K4 connects to cavity A4 of the PCM. • Camshaft position sensor
The governor pressure sensor is part of the trans • Engine coolant temperature sensor
mission solenoid assembly. • Intake air temperature sensor
• Throttle position sensor
TRANSMISSION TEMPERATURE SENSOR • Manifold absolute pressure sensor
The transmission temperature sensor is located in • Vehicle speed sensor
the transmission solenoid assembly. The Powertrain
Control Module (PCM) supplies 5 volts to the sensor FOUR-WHEEL DRIVE INDICATOR
on circuit K7. Circuit T34 from the sensor connects to Power for the four-wheel drive indicator lamp is
cavity B l of the PCM and provides the transmission supplied on circuit F14. Circuit G107 connects the
temperature input. The PCM provides ground for the lamp to the four-wheel drive switch. When the switch
sensor on cavity K4. closes, circuit G107 connects to ground on circuit Z l .
The PCM grounds the transmission temperature
warning lamp on circuit G14. Circuit G14 connects to
cavity C7 of the PCM. The transmission temperature SCHEMATICS AND DIAGRAMS
warning lamp is located in the message center.
HELPFUL INFORMATION The following index covers all components found in
Circuit K7 also supplies 5 volts to the vehicle speed this section of the wiring diagrams. If the component
sensor. you are looking for is not found here, refer to section
Circuit K4 also provides ground for the signals 8W-02 for a complete list of all components shown in
from the following: the wiring diagrams.
BR 8W-31 TRANSMISSION CONTROLS 8W - 31 - 3
DIAGRAM INDEX
Controller Anti-Lock Brake 8W-31-8 Ignition Switch 8W-31-4, 6
Four Wheel Drive (4WD) Switch 8W-31-8 Instrument Cluster 8W-31-7.8
Fusel (PDC) 8W-31-6 Joint Connector A 8W-31-6
Fuse 3 (PDC) 8W-31-4.6 Joint Connector C 8W-31-6
Fuse 8 (PDC) 8W-31-4 Overdrive Switch 8W-31-7
Fuse 9 8W-31-4 Powertrain Control Module 8W-31-4, 5, 7
Fuse 11 8W-31-6 Transmission Output Shaft Speed Sensor 8W-31-7
Fuse 13 8W-31-6 Transmission Relay 8W-31-4
Fuse 18 8W-31-6 Transmission Solenoid Assembly 8W-31-4, 5
Headlamp Switch 8W-31-6
8040d054 J968W-9
8W-31 -4- 8W-31 TRANSMISSION CONTROL BR
AO 6RD
BATTERY
POSITIVE
TERMINAL
<8W-2Q-3,4)
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH
DIESEL ENG)
(8W-20-4)
* WITH GAS ENG

** WITH DIESEL ENG
8040(1055 J968W-9
BR- 8W-31 TRANSMISSION CONTROLS 8W - 31 - 5
(WITH AUTO TRANS)
TRANSMISSION C125
RELAY -T16 18RD-
(8W-31-4)
T16
18RD
^ C167
TRANSMISSION
TRANS CONTROL
SOLENOID
RELAY OUTPUT ASSEMBLY
TORQUE
VARIABLE CONVERTER TRANS
GOVERNOR FORCE OVERDRIVE CLUTCH TEMP
5 VOLT SENSOR PRESSURE SOLENOID SOLENOID SOLENOID SENSOR
SUPPLY GROUND SIGNAL CONTROL CONTROL CONTROL SIGNAL
2 3 4 5 6 7 8
TK7
T-K4
€167
180R
18BK
S130 LB WITH
DIESEL
8W-70-12
I ENG
K7 T25 K88 T60 K54 T54

K4
180R 20LG 20VT 20BR 200R 18VT
18BK
WT WT BK
LB
S154
8W-70-23
K4 K4
18BK 18BK
LB LB
S129 S157
8W-70-12 8W-70-25
K4 K4
20BK 20BK
LB LB
?
K4
20BK
LB
C136 ^ C135 C136

POWERTRAIN
B31 A4 B29 B8 B21 Bll Bl CONTROL
5 VOLT SENSOR GOVERNOR VARIABLE OVERDRIVE TORQUE TRANS MODULE
SUPPLY GROUND PRESSURE FORCE SOLENOID CONVERTER TEMP
SIGNAL SOLENOID CONTROL CLUTCH SENSOR
CONTROL SOLENOID SIGNAL
CONTROL
8040d057 J968W-9
8W - 31 - 6 8W-31 TRANSMISSION CONTROLS BR
POWER
DISTRIBUTION
BATTERY CENTER
POSITIVE
TERMINAL
(8W-20-3,4) AO
6RD
AO FUSE 1 C180
AO AO 20BK*
OERD 6RD* -O^r* ) > - A 7 10RD/BK
50A
RIGHT emit- (1)
BATTERY AO
AO
POSITIVE OOERD**
14PK**
TERMINAL S147
(WITH FUSE 3 C180 8W-70-21
DIESEL ENG)
'(811-20-4) 40A (3)
SPLICE
S148 Al
(8W-70-21) 12RD
ENGINE
STARTER A7
MOTOR 12RD
(8W-21-3.4) BK
C133
S124
8W-70-12 « §133
- A l 12RD- • A l 12RD-
A7
12RD
(7): C212 BK
IGNITION -A7 12RD/BK•
START \ ACC
SWITCH S204 J
...V
RUN OFF
A7
12RD
A7
m— 12RD-
8W-70-28
A7
-12RD-
BK
BK BK
JOINT
PARK
FUSE WITH CONNECTOR
(2) C212 POWER SEAT
LAMP
A
(31) C241 (14) C241 BLOCK SWITCH
A21 OUTPUT
12DB
FUSE FUSE (10): C217
11 <? 18
10A 15A HEADLAMP
SWITCH
(35): C241 (18): C241
-F12 22DB/WT-
L
F33 20PK/RD
(12): C209
JOINT
CONNECTOR
C
(14): C209 FUSE 13 C241

G-^Xs* )>
F12
22DB 5A (21)
WT JOINT
C209 FUSED PANEL CONNECTOR
E2 200R- LAMPS DIMMER C
(5) SWITCH SIGNAL
OVERDRIVE REF TO
SWITCH OVERDRIVE WITH FOG LAMPS
(8W-31-7) SWITCH
ILLUMINATION FOG LAMP * WITH GAS ENG
LAMP E2 2 2 0 R - SWITCH * * WITH DIESEL ENG
C8W-31-7) (8W-50-10)
8040d059 J968W-9
BR® 8W-31 TRANSMISSION CONTROLS 8W - 31 - 7
JOINT
CONNECTOR
C -F12 22DB/WT-
(8W-3I-6)
(8W-12-7)
S215
8W-70-33 1202
Z3 Z3
-20BK- -12BK- 8W-15-13
OR OR
(2)< (3)- C225

OVERDRIVE
SWITCH
(WITH
AUTO
FUSE IND TRANS)
BLOCK
(8W-31-6)
(8W-10-11)
(5): C225
200R NOT FUNCTIONAL

WITH AUTO
TRANS
WITH
FOG
T6
LAMPS INSTRUMENT
220R
WT CLUSTER
JOINT FOG
CONNECTOR LAMP
C8W 33 6 ) SWITCH
(8W-12-6) (8W-50-10)
C133
WITH MAN TRANS

(EXCEPT HEAVY
TRANSMISSION OUTPUT WITH DUTY)
SHAFT SPEED SENSOR AUTO (EXCEPT 8 . 0 L
T6 TRANS AND DIESEL ENG)
(WITH AUTO TRANS) 220R (USED FOR UPSHIFT
WT T18 654 INDICATOR LAMP)
! OUTPUT OUTPUT ! 20LG 200R
i SHAFT SHAFT ! OR BK
,' SPEED SPEED i
i SENSOR SENSOR J
j GROUND SIGNAL •
C125
(2): (1): C187
T13 T14 T6
18DB 18LG 200R
BK BK WT
C136 C137 C136

POWERTRAIN POWERTRAIN
B25 B28 C13 C6 Bll
CONTROL CONTROL
OUTPUT OUTPUT TRANS OD UPSHIFT
SHAFT SHAFT OD LAMP
MODULE LAMP MODULE
SPEED SPEED SWITCH DRIVER DRIVER
SENSOR SENSOR SENSE
GROUND SIGNAL
8040d05b J968W-9
8W-31 8° 8W-31 TRANSMISSION CONTROLS BR
INSTRUMENT
CLUSTER
(13) • C215
CONTROLLER
WITH
ABS " •6107 20BK/GY-
6107 6107 20BK/6Y-

22BK
GY
C133 C133
6107 20BK/GY-
C106
•6107 20BK/6Y-
6107 20BK/GY-
6107
18BK
6Y
WITH
ABS
(1) >jS C407
411
SWITCH
(2): C407
Zl
18BK
C106
(ABS)
S103 Zl
8W-70-3 20BK
•Zl 18BK-
0102
18W-15-41
8040d05e J968W-9
BR 8W - 33 VEHICLE SPEED CONTROL 8W - 33 -1
8W-33 V E H I C L E SPEED CONTROL
DESCRIPTION AND OPERATION nominal value of 4.4 volts with a range from 4.2 to
4.5 volts.
VEHICLE SPEED CONTROL The PCM controls the vent and vacuum functions
The Powertrain Control Module (PCM) operates of the vehicle speed control servo on circuits V35 and
the vehicle speed control system. The vehicle speed V36. Depending on the signal it receives from vehicle
control switches are located in the steering wheel, speed control switches, the PCM either applies vac
below the airbag. uum to or vents vacuum from the servo. Circuit V36
Circuit ¥ 3 2 from cavity C l l of the PCM supplies from cavity C4 of the PCM sends the vacuum signal
voltage to the Light Emitting Diode (LED) used for to the servo. Circuit V35 from cavity C5 sends the
the speed control indicator lamp and to the speed vent signal.
control switches. Circuit V32 also connects to circuit Circuit V40 provides the stop lamp switch sense
V30 through the stop lamp switch. Circuit V30 pow input to the PCM at cavity C24. The stop lamp
ers the vehicle speed control servo. switch connects circuit V40 to ground on circuit Z l l .
Circuit V37 from PCM cavity C32 connects to the When the brake pedal is depressed, the stop lamp
vehicle speed control switches. The switches are switch opens and disconnects circuits V40 and Z l ,
wired in parallel and each contains a separate resis and circuits V32 and V30. When the stop lamp
tor. The voltage level present on circuit V37 (at PCM switch disconnects circuits V32 and V30, power is
cavity C32) depends on which speed control switch is removed from the speed control servo.
selected. Circuit K 4 from PCM cavity A4 supplies
ground for the speed control switches. HELPFUL INFORMATION
• When the ON/OFF switch is open, the voltage Circuit K 4 also provides ground for some of the
level on circuit V37 at PCM cavity C32 has a nomi engine control sensors that provide inputs to the
nal value of 5.0 volts with a range from 4.8 to 5.0 PCM.
volts.
• When the ON/OFF switch closes, the voltage SCHEMATICS A N D DIAGRAMS
level on circuit V37 at PCM cavity C32 has nominal
value of 1.51 volts with a range from 1.31 to 1.61 WIRING DIAGRAM INDEX
volts. The following index covers all components found i n
• When the SET/COAST switch closes, the voltage this section of the wiring diagrams. I f the component
level on circuit V37 at PCM cavity C32 has nominal you are looking for is not found here, refer to section
value of 3.8 volts with a range from 3.6 to 3.9 volts. 8W-02 for a complete list of all components shown i n
• When the RESUME/ACCEL switch closes, the the wiring diagrams.
voltage level on circuit V37 at PCM cavity C32 has
8W - 33 - 2 8W-33 VEHICLE SPEED CONTROL BR
DIAGRAM INDEX
Controller Anti-Lock Brake 8W-33-4 Stop Lamp Switch 8W-33-4
Joint Connector C 8W-33-3.4 Vehicle Speed Control Servo 8W-33-4
Powertrain Control Module 8W-33-3, 4 Vehicle Speed Control/ Horn Switch 8W-33-3
8040d060 J968W-9
8W-33 VEHICLE SPEED CONTROL 8W - 33 - 3
VEHICLE SPEED
CONTROL/
R4 R2 Rl R3 HORN SWITCH
909O 15.4KO 6.65KO 806O
RESUME/ SET/
— ON/OFF I—
ACCEL !
COAST
#1
O— L.E.D.
(3) (1)_ C203
K4
T
V37
K4 18BK 22RD
20BK LB LG
LB
C133
K4 K4 C133
C125
20BK 20BK K4
LB LB JOINT
20BK CONNECTOR
LB V37 C
SIS4 K4
20BK 20RD
8W-70-23 LB LG
S156
K4 8W-70-24
18BK C126
LB SIS?
8W-70-25
S129
8W-70-12 V37
WITH 20RD
DIESEL LG
ENG STOP LAMP
K4 K4 SWITCH
20BK 20BK (8W-33-4)
LB LB
C126
V32
20YL
RD
C137
POWERTRAIN
C32 Cll
SPEED SPEED CONTROL
CONTROL CONTROL MODULE
C135 SWITCH FEED
SENSOR
•K4 20BK/LB• A4 GROUND SIGNAL
8040d063 J968W-9
8W-33-4 8W-33 VEHICLE SPEED CONTROL BR
STOP LAMP
SWITCH
C214 C214 CONTROLLER

BRAKE ANTI-LOCK
-<f SWITCH
(21 (D: SENSE BRAKE
7 (RWAL)
Zll
20BK ^ C228
WT !(f
(61 (5)j V32 V40 V40
20YL 20WT 22WT
•V30 20DB/RD- PK
RD PK
(4) (3)
C133 (17) (32)- (33)^ C209
S208
JOINT
8W-70-30
CONNECTOR
C
Zll
V30 18BK
20DB WT
RD
G202 (18): (19): J31)sfe C209
8W-15-13 V40
(3) ctm V32 22WT
VEHICLE 22YL PK
SPEED RD
CONTROL SPEED
ON/OFF CONTROL ^ C133
SPEED SPEED
SWITCH CONTROL CONTROL SERVO
OUTPUT VACUUM VENT VEHICLE 1
SOLENOID SOLENOID SPEED WITH
GROUND CONTROL CONTROL CONTROL/ V40 ABS
(4) (1) (2) HORN 20WT
2V
C109 SWITCH PK
C8W-33-3) Sill
V40 8W-70-6
22WT
Zl V36 V35 V32 PK
20BK 20TN 20LG 22YL
RD RD RD
V40
20WT V40
PK 20WT
S108 PK
C133
8W-70-5
C126 ^ C121
V32 9 CONTROLLER
20YL BRAKE ANTI-LOCK
RD SWITCH BRAKE
SENSE (ABS)
Zl
12BK V36 V35 C126
20TN 20LG C125
RD RD
V32
20YL V40
G101 RD 20WT
8W-15-3 PK
C137 C137
C4 C5 Cll C24 POWERTRAIN
SPEED SPEED SPEED BRAKE CONTROL
CONTROL CONTROL CONTROL SWITCH MODULE
VACUUM VENT FEED SENSE
SOLENOID SOLENOID
CONTROL CONTROL
8040d066 J968W-9
BR 8W - 34 REAR WHEEL ANTI-LOCK BRAKES 8W - 34 -1
8W-34 R E A R W H E E L A N T I - L O C K B R A K E S
INDEX
page page
DESCRIPTION AND OPERATION RWAL VALVE . 1

BRAKE WARNING LAMP SWITCH INPUT 2 STOP LAMP SWITCH INPUT . . . 1
DATA LINK CONNECTOR 1 VACUUM SENSOR . . . . . . . . . ....... 2
FOUR-WHEEL DRIVE SWITCH SENSE 1 WARNING LAMP . 1
INTRODUCTION 1 SCHEMATICS AND DIAGRAMS "'
PARK BRAKE SWITCH INPUT 1 WIRING DIAGRAM INDEX .2
REAR WHEEL SPEED SENSOR 1
DESCRIPTION A N D OPERATION Circuit B108 from cavity 8 of the CAB feeds the
dump solenoid. The isolation solenoid is powered on
INTRODUCTION circuit B101 from cavity 1 of the CAB. Circuit Z8
Power for the Controller Anti Lock Brake (CAB) is provides ground for both solenoids.
supplied on circuit A20. This circuit is connected to Circuit B i l l from cavity 11 of the CAB connects to
the fuse block and protected by a 20 amp fuse located the reset switch. The case grounded RWAL valve pro
in cavity 14. Power for the fuse is supplied on circuit vides ground for the reset switch.
A22 from the ignition switch. This circuit is HOT in
the START/RUN position only. WARNING. LAMP
Power for the A22 circuit is supplied by circuit A2. The Controller, Antilock Brake (CAB) provides
This circuit originates at the Power Distribution Cen ground for the instrument cluster Check Antilock
ter (PDC) and is protected by a 40 amp fuse located warning lamp on circuit G19. Circuit F14 provides
in cavity 2. voltage to the instrument cluster to feed the warning
On diesel engines circuit A20 is double crimped at lamp.
cavity 3 of the CAB and provides battery voltage to
the vacuum switch. iATA LINK CONNECTOR
Circuit F32 also provides battery voltage to the Circuit B112 from cavity 12 of the Controller Anti
CAB. Circuit F32 is HOT at all times. Fuse 20 in the Lock Brake (CAB) connects to the universal data link
fuse block protects circuit F32. Circuit A3 from the connector. Circuit 113 also connects to the universal
PDC feeds the fuse block bus bar that powers fuse 20 data link connector. This circuit is double crimped at
and circuit F32. Fuse 6 in the PDC protects circuit cavity 14 of the CAB. Refer to Group 5, Brakes, for
A3. Circuit Z3 provides ground for the CAB. more information.
REAR WHEEL SPEED SENSOR FOUR-WHEEL DRIWE SWITCH SENSE

The rear wheel speed sensor is mounted on the top From circuit G107, the Controller Antilock Brakes
of the rear axle differential. The sensor converts (CAB) senses when the four-wheel drive switch
wheel speed into an electrical signal that it transmits CLOSES. Circuit G107 connects to cavity 4 of the
to the Controller Anti Lock Brake (CAB). CAB.
Circuits B113 and B114, a pair of twisted wires,
connect to the sensor to provide signals to the CAB. STOP LAMP SWITCH INPUT
The B113 circuit also connects to the universal data Circuit V40 provides an input to the Controller
link connector. Anti Lock Brake (CAB) as to when the operator is
Circuit B113 connects to cavity 14 of the CAB. Cir applying the brakes. The V40 circuit connects to cav
cuit B114 connects to cavity 13 of the CAB. ity 7 of the CAB.
RWAL WALWE PARI BRAKE SWITCH INPUT

The rear wheel anti-lock (RWAL) valve contains an On circuit G i l , the Controller Anti Lock Brake
isolation solenoid, a dump solenoid and a reset (CAB) senses when the park brake switch CLOSES.
switch. Each is powered by the Controller Anti Lock Circuit G i l from the park brake switch connects to
Brake (CAB) on separate circuits. cavity 5 of the CAB.
8W - 34 - 2 8W - 34 REAR WHEEL ANTI-LOCK BRAKES BR
DESCRIPTION ANDOPERATION (Continued)
BRAKE WARNING LAMP SWITCH INPUT lem i n the system; the sensor grounds circuit G9 and
Circuit G9 provides an input to the Controller Anti the red brake warning lamp in the instrument clus
Lock Brake (CAB). The CAB receives the input when ter is illuminated.
either the ignition switch is i n the START position,
or the park brake warning lamp switch in the
hydraulic combination valve CLOSES.
VACUUM SENSOR
The vacuum sensor is used on the diesel engine The following index covers all components found in
only. Power for the sensor is supplied on circuit A20. this section of the wiring diagrams. I f the component
This circuit is HOT i n the RUN position only and you are looking for is not found here, refer to section
protected by a 2 0 amp fuse located i n cavity 14 of the 8 W - 0 2 for a complete list of all components shown i n
fuse block. Ground for the switch is supplied on cir the wiring diagrams.
cuit Z l .
Circuit Z l connects to the vacuum sensor and sup
plies a ground path for circuit G 9 . I f there is a prob
BR 8W-34 REAR WHEEL ANTI-LOCK BRAKES 8W - 34 - 3
DIAGRAM INDEX
Brake Switch 8W-34-4 Ignition Switch 8W-34-4
Controller Anti-Lock Brake 8W-34-4, 5, 6, 7 Instrument Cluster 8W-34-4, 6
Data Link Connector 8W-34-7 Joint Connector B 8W-34-5
Daytime Running Lamp Module 8W-34-6 Joint Connector C 8W-34-4, 5, 6
Four Wheel Drive (4WD) Switch 8W-34-6 Park Brake Switch 8W-34-6
Fuse 2 (PDC) 8W-34-4 Powertrain Control Module 8W-34-5
Fuse 6 (PDC) 8W-34-5 Rear Wheel Speed Sensor 8W-34-7
Fuse 14 8W-34-4 RWAL Valve 8W-34-7
Fuse 20 8W-34-5 Stop Lamp Switch 8W-34-5
Ground Joint 8W-34-4 Vacuum Sensor 8W-34-4
8040d068 J968W-9
8W-34-4 8W-34 REAR WHEEL ANTI-LOCK I R A K I S mm
AO 14PK**- SPLICE
S148
BATTERY ENGINE (8W-70-21)
POSITIVE AO'OOERD**- STARTER
TERMINAL MOTOR
<8W-20-3,4) <8W-21-3,4)
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH DIESEL
ENG)
C8W-20-4)
(WITH DIESEL ENG)

$109
FUSED RED
C134 BRAKE C134 8W-70-5
IGN SW
"A20 18RD/DB" OUTPUT WARNING •G9 20GY/BK-
(3) (RUN) LAMP (2)
DRIVER G9
GROUND GND WITH 16GY
JOINT DIESEL-— BK
ENG
C123 r - "! C 1 2 3
•G9 20GY/BK-
(£-! GND GND r » - Z l 18BK J C133
C133
(4) (5)
A20 BLACK
18RD G9
22GY •G9 18GY/BK-
DB WITH BK
A20 HIGH-LINE AND
18RD Zl MEDIUM-LINE
DB 12BK CLUSTER
S108 JOINT CONNECTOR C (26) : C209
Zl BRAKE
14BK 8W-70-5 C209 SWITCH
Zl
12BK (24)
(23): (25) : C209
G9
22GY G9 22GY/BK- CASE
G101 BK G9 GROUND
• 8W-15-3 22GY
BK (3): C212
i IGNITION
4 START ! SWITCH
C228 (4) : C216
RUN
CONTROLLER INSTRUMENT
3 6
ANTI-LOCK RED
CLUSTER
FUSED RED BRAKE BRAKE
IGN SW BRAKE WARNING OFF N
OUTPUT WARNING LAMP m CASE

ACC GROUND
(RUN) LAMP DRIVER
DRIVER
* WITH GAS ENG
** WITH DIESEL ENG
8040d06a J968W-9
BR- 8W-34 REAR WHEEL ANTI-LOCK BRAKES 8W - 34 - 5
SPLICE
S148
BATTERY (8W-70-21)
POSITIVE
TERMINAL
C8W-20-3,4)
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH DIESEL
ENG)
(8W-20-4)
* WITH GAS ENG

** WITH DIESEL ENG
8040d06c J968W-9
8W - 34 - 6 8W-34 REAR WHEEL ANTI-LOCK BRAKES BR
( 2 ) C 4 0 7
4WD Zll
SWITCH 18BK
C106
(1): C407
611 Gil Zl
22WT 22WT 20BK
BK BK G107
18BK
GY
S103
8W-70-3
(11): (10): C209

C106
JOINT Zl
CONNECTOR 18BK
C G107
20BK
GY 0102
8W-15-4
(9): (8): C209
Gil INSTRUMENT
20WT | ABS CLUSTER
BK i WARNING C133
! LAMP 4WD |
BLACK
| DRIVER LAMP »
(14): (13): C215
Gil G19 G107

22WT 22LG 20BK
BK PARK RD GY
BRAKE
SWITCH
CASE
GROUND
5 2 4
CONTROLLER
PARK ABS 4WD
ANTI-LOCK
BRAKE WARNING SENSE
BRAKE
SWITCH LAMP
SENSE DRIVER
8040d06e J968W-9
BR 8W-34 REAR WHEEL ANTI-LOCI BRAKES 8W *» 34 - 7
REAR WHEEL
SPEED SENSOR
C409
RNAL
B113
20RD
VT
TWISTED CASE
PAIR GROUND
C330
B114 B113
20WT 20RD
VT VT
TWISTED
PAIR
DATA LINK
C128 CONNECTOR
RIGHT
REAR
B114 B113 WHEEL RWAL C133
20WT 20RD SPEED SERVICE
VT VT SENSOR DIAG
(+) SIGNAL
TWISTED (9): (13): C223
PAIR
£ C133
B113 B112 Bill B108 B101

TWISTED 20 RD 20BK 22LB 18WT 18LG
PAIR VT BK WT
B114
22WT
VT
C228 C228
CONTROLLER
13 14 12 11 8 1 ANTI-LOCK
RIGHT RIGHT RWAL RWAL RWAL RWAL BRAKE
REAR REAR SERVICE RESET DUMP ISOLATION
WHEEL WHEEL DIAG SWITCH SOLENOID SOLENOID
SPEED SPEED SIGNAL
SENSOR SENSOR
(-) (+)
8040d070 J968W-9
BR 8W - 35 ALL-WHEEL ANTI-LOCK BRAKES 8W - 35 - 1
8W-35 ALL-WHEEL A N T I - L O C K BRAKES
INDEX
page page
DESCRIPTION AND OPERATION INTRODUCTION ...... . 1

ABS PUMP RELAY 1 REAR WHEEL ANTILOCK (RWAL) VALVE . . . . . . 2
ABS WARNING LAMP , 2 STOP LAMP SWITCH SENSE 2
BRAKE WARNING LAMP SWITCH INPUT 2 VACUUM SENSOR 2
DATA LINK CONNECTOR 2 WHEEL SPEED SENSORS . 1
FOUR-WHEEL DRIVE SWITCH SENSE . . . . 2 SCHEMATICS AND DIAGRAMS
HYDRAULIC CONTROL UNIT 1 WIRING DIAGRAM INDEX 2
DESCRIPTION A N D OPERATION CAB. Circuit B9 connects to cavity 3 of the CAB and

provides the HIGH signal.
INTRODUCTION Circuit B114 connects to cavity 14 of the CAB and
Three fuses supply power for the' Anti-Lock Brake to the rear wheel speed sensor. Circuit B113 connects
System (ABS); fuses 2 and 5 in the Power Distribu to cavity 1 of the CAB and to the rear wheel speed
tion Center (PDC) and fuse 14 i n the fuse block. sensor. Circuit B114 provides the rear wheel speed
Fuses 2 and 5 in the PDC are connected directly to sensor LOW input while circuit B113 provides the
battery voltage and are HOT all times. Fuse 14 is HIGH input.
HOT when the ignition switch is the RUN position.
In the RUN position, the ignition switch connects ABS PUMP RELAY
circuit A2 from a 40 amp fuse in cavity 2 of the PDC When the Controller Anti Lock Brake (CAB)
with circuit A22. Circuit A22 connects to a bus bar in grounds the ABS pump relay oh circuit B116, the
the fuse block. The bus bar feeds circuit A20 through relay contacts CLOSE connecting circuit A10 from
fuse 14. Fuse 14 is a 40 amp fuse. the Power Distribution Center (PDC) and circuit
Circuit A20 is spliced and connects to the Control B120. Circuit A10 connects to fuse 5 in the PDC. Cir
ler Anti Lock Brake (CAB), feeds the coil sides of the cuit A20 from the fuse 14 in the fuse block splices to
ABS pump relay and ABS warning lamp relay, and feed the coil side of the ABS warning lamp relay and
on diesel engines, feeds the vacuum sensor. the pump motor relay.
Circuit Z7 provides ground for the ABS control From the ABS pump relay, circuit B120 splices to
module. Circuit Z7 connects to cavity 20 of the CAB supply voltage to the ABS pump motor and all sole
connector. noids i n the hydraulic control unit. Circuit B120 also
supplies power to the solenoids i n the Rear Wheel
WHEEL SPEED SENSORS Anti Lock (RWAL). valve. Additionally, circuit B120
The all wheel Anti-Lock Brake System (ABS) uses provides an input to cavity 34 of the CAB. The input
three wheel speed sensors; a single sensor for both tells the CAB that voltage has been supplied to the
rear wheels and individual sensors for the front pump motor.
wheels. The single sensor used for the rear'wheels
mounts on the top of the rear axle differential hous HYDRAULIC CONTROL UNIT
ing. Each sensor converts wheel speed into an' elec Circuit B120 from the ABS pump relay supplies
trical signal that i t transmits to the Controller Anti voltage for the ABS pump motor plus the isolation
Lock Brake (CAB). A pair of twisted wires connect to and dump solenoids. in the. hydraulic control unit.
each sensor and provide signals to the CAB. The Controller Antilock Brake (CAB) activates the
Circuits B6 and B7 provide signals to CAB from pump motor and the solenoids by providing separate
right front wheel speed sensor. Circuit B6 which pro ground paths for each.
vides the LOW signal, connects to cavity 15 of the The CAB provides a ground path for the motor on
CAB. Circuit B7 connects to cavity 2 of the CAB and circuit B60. Circuit B60 connects to the CAB two-way
provides the HIGH signal. connector.
Circuits B8 and B9 provide signals to CAB from The CAB cycles the isolation and dump solenoids
left front wheel speed sensor. Circuit B8 which pro in the front anti-lock valve by providing a ground
vides the LOW signal, connects to cavity 16 of the path for each on separate circuits:
8W - 35 - 2 8W - 31 ALL-WHEEL ANTI-LOCI 1RA1ES BR
• Circuit B248 connects to cavity 30 of the CAB BRAKE WARNING LA1P SWITCH INPUT
and provides ground for the right front dump sole Circuit G9 provides an input to the Controller Anti
noid. Lock Brake (CAB). The CAB receives the input when
• Circuit B249 connects to cavity 33 of the CAB either the ignition switch is i n the START position,
and provides ground for the right front isolation sole the park brake switch CLOSES or the brake warning
noid. lamp switch in the hydraulic combination valve
• Circuit B243 connects to cavity 35 of the CAB CLOSES.
and provides ground for the left front dump solenoid.
• Circuit B245 connects to cavity * 37 of the CAB STOP LAMP SWITCH SENSE
and provides ground for the left front isolation sole On circuit V40, the Controller Anti Lock Brake
noid. (CAB) senses when the brake pedal has been
There are two reset switches i n the hydraulic con pressed. Circuit V40 connects to cavity 9 of the CAB
trol unit; a left switch and a right switch, both pro and splices to the stop lamp switch and the Power-
vide inputs to the CAB. Circuit B5 from the left reset train Control Module (PCM).
switch connects to CAB cavity 5 while circuit B18
from the right reset switch connects to cavity 18. FOUR-WHEEL DRIWE SWITCH SENSE
From circuit G107, the Controller Antilock Brake
HELPFUL INFORMATION (CAB) senses when the four-wheel drive indicator
The front anti-lock valve is case grounded. lamp switch closes. Circuit G107 connects to cavity 8
of the CAB and splices to the four-wheel drive indi
REAR WHEEL ANI1L0C1 (RWAL) ¥AL¥E cator lamp switch and instrument panel four-wheel
Circuit B120 from the ABS pump relay supplies drive indicator lamp.
voltage for the isolation and dump solenoids in the
Rear Wheel Antilock (RWAL) valve. The Controller DATA LINI CONNECTOR
Antilock Brake (CAB) activates the solenoids by pro The DRB scan tool connects to the data link con
viding separate ground paths for each. nector. Circuits D l l and D12 from the Controller
• Circuit B254 connects to cavity 26 of the CAB Antilock Brake (CAB) connect to the data link con
and provides ground for the rear dump solenoid. nector. Circuit D12 connects to cavity 10 of the CAB.
• Circuit B252 connects to cavity 28 of the CAB The CAB transmits data to the DRB scan tool on cir
and provides ground for the rear isolation solenoid. cuit D12.
The RWAL valve has one reset switch that pro The DRB scan tool receives data from the CAB on
vides an input to the CAB. Circuit B19 from the circuit D l l . Circuit D l l connects to cavity 11 of the
reset switch connects to CAB cavity 19. CAB.
ABS WARNING LAMP ¥ACUU1 SENSOR
The Controller, Antilock Brakes (CAB) provides The vacuum sensor is used on the diesel engine
ground for the ABS warning lamp in the message only. Power for the sensor is supplied on circuit A20.
center * through the normally closed contacts i n the This circuit is HOT in the RUN position only and
ABS warning lamp relay. When the ignition switch is protected by a 20 amp fuse located i n cavity 14 of the
in the START position, the lamp illuminates as a fuse block. Ground for the switch is supplied on cir
bulb test for approximately 3 to 5 seconds while the cuit Z l .
CAB performs a system self-test. While closed, the Circuit Z l connects to the vacuum sensor and sup
relay contacts complete the ground path for the ABS plies a ground path for circuit G9. I f there is a prob
warning lamp by connecting circuit G19 from the lem i n the system, the sensor grounds circuit G9 and
lamp to ground on circuit Z l . Power for the lamp is the red brake warning lamp i n the instrument clus
supplied by circuit F14. ter is illuminated.
If the system self-test is successfully completed,
the CAB energizes the ABS warning lamp relay by
providing ground for the relay coil on circuit B47. SCHEMATICS AND DIAGRAMS
When the relay energizes, its contacts open and dis
connect circuits G19 and Z l . Circuit A20 from fuse 14 WIRING DIAGRAM INDEX
in the fuse block supplies power to the coil side of the The following index covers all components found in
relay. this section of the wiring diagrams. I f the component
Circuit G19 from the ABS warning splices to the you are looking for is not found here, refer to section
ABS warning lamp and the CAB. 8W-02 for a complete list of all components shown in
BR 8W-35 ANTI- LOCK BRAKES — 8W - 35 - 3
DIAGRAM INDEX
Component P a
P Component Page
ABS 2-Way Power Feed 8W-35-9 Fuse 14 8W-35-4, 5
ABS Pump Motor Relay 8W-35-6 Ground Joint 8W-35-5
ABS Warning Lamp Relay 8W-35-6 Hydraulic Control Unit 8W-35-9
Brake Switch 8W-35-5 Ignition Switch 8W-35-4, 5
Controller Anti-Lock Brake 8W-35-4 thru 10 Instrument Cluster 8W-35-5, 6, 7
Data Link Connector 8W-35-7 Joint Connector C 8W-35-5, 7
Four Wheel Drive (4WD) Switch 8W-35-7 Powertrain Control Module 8W-35-7
Front Wheel Speed Sensors 8W-35-8 Rear Wheel Speed Sensor 8W-35-8
Fuse 2 (PDC) 8W-35-4, 5 RWAL Valve 8W-35-10
Vacuum Sensor 8W-35-5
8040d072 J968W-9
8W - 3 5 - 4 - 8W-35 ANTI-LOCK BRAKES BR
BATTERY AO 6RD-
POSITIVE
TERMINAL
C8W-20-3,4)
RIGHT
BATTERY
POSITIVE
AO
TERMINAL
OOERD**
(WITH DIESEL
ENG)
(8W-20-4)
t
ENGINE ' SPLICE
STARTER S148
MOTOR (8W-70-21)
<8W-21-3,4)
FUSE
VACUUM
SENSOR
(8W-35-5)
ABS
PUMP
MOTOR
RELAY
C8W-35-6)
CONTROLLER (8W-11-16)
ANTI-LOCK
FUSED I G N I T I O N BRAKE A20
SWITCH OUTPUT
18RD
(RUN)
DB
ABS
GND WARNING
20
LAMP
^ C121 RELAY
(8W-35-6)
17 (8W-11-16)
18BK
RD
G107
8W-15-9
* WITH GAS ENG
** WITH DIESEL ENG
8040d073 J968W-9
8W-35 ANIi-LOCK BRAKES 8W - 35 - 5
SPLICE
S148
BATTERY (8W-70-21)
POSITIVE
TERMINAL
<8W-20-3,4)
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH DIESEL
ENG)
(8*4-20-4)
WITH
LOW-LINE
CLUSTER
CASE
GROUND
CASE
GROUND * WITH GAS ENG
* * WITH DIESEL ENG
8040d075 J968W-9
8W-35.--G- 3W-35 ANTI-LOCK BRAKES
BATTERY SPLICE
POSITIVE i -AO 20BK* AO 14PK** S148
TERMINAL (8W-70-21)
(8W-20-3,4) ENGINE S T A R T E R
MOTOR
RIGHT <8W-21-3,4)
BATTERY
POSITIVE
TERMINAL
(WITH DIESEL
ENG)
(8W-20-4)
! 34 4
J ABS ABS
BRAKE
i PUMP PUMP
! MOTOR MOTOR
i RELAY RELAY
1
RWAL OUTPUT CONTROL
VALVE
CLUSTER (8W-35-10)
* WITH GAS ENG
** WITH DIESEL ENG
8040d077 J968W-9
BR 8W-35 ANTI-LOCK BRAKES 8W - 35 - 7
C209 r JOINT
CONNECTOR
V40 (32) C
20WT C209
C214 PK (31)
V40
i STOP 22WT
$ LAMP PK
( 5 ) | SISTCH
C133
V40
20WT
PK
Sill $103
V40 20WT/PK I 8W-70-6 8W-70-3
Z l 18BK-
G102
8W-15-4
POWERTRAIN C106
CONTROL
MODULE
INSTRUMENT
' DATA CLUSTER
i SCI SCI i LINK i 4WD
i
1 TRANSMIT RECEIVE i CONNECTOR i 4WD SWITCH
LAMP
(15) JJ31^ C223
(13) : C215
D12 Dll V40 G107

220R 22WT 20WT 22BK
RD PK GY
C133 C106
C133 C133
G107
20BK
GY S105
D12 Dll 8W-70-4
200R 20WT
RD
G107
20BK
GY
" " ^ C121

10 11 9 8 CONTROLLER
SCI SCI BRAKE 4WD ANTI-LOCK
TRANSMIT RECEIVE SWITCH SENSE BRAKE
SENSE
8040d078 J968W-9
8W - 35 - 8 8W-35 ANTI-LOCK BRAKES BR
LEFT FRONT
C330 C330 TWISTED TWISTED

PAIR PAIR
B113 B114
20RD 20WT
VT VT
TWISTED
PAIR
C128 C128
I
B113 B114
20RD 20WT
VT VT
TWISTED
PAIR
C121
1 14 2 15 3 16 } CONTROLLER
RIGHT RIGHT RIGHT RIGHT LEFT LEFT ANTI- LOCK
REAR REAR FRONT FRONT FRONT FRONT BRAKE
WHEEL WHEEL WHEEL WHEEL WHEEL WHEEL
SPEED SPEED SPEED SPEED SPEED SPEED
SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR
(+) (-) (+) (-) (+) (-)
8040d07a J968W-9
BR- 8W-35 ANTI-LOCK BRAKES 8W - 35 - S
ABS PUMP HYDRAULIC CONTROL UNIT

MOTOR RELAY
C8W-35-6)
(8W-11-16)
B120
12BR
WT CASE
GROUND ( )
9
RWAL
VALVE
12BR
B120 12BR/WT
WT
$112
8W-70-7
-B120 12BR/WT-—
L—B120 12BR/WT—>
B120 B5 B245 B243 B18 B249 B248 B60

14BR 20VT 18WT 16DG 20VT 18WT 16DG 12LB
WT RD LG BK LG TN WT BK
(B) C120
PUMP/MOTOR
ABS
CONTROL 2-WAY
POWER
GND FEED
(A) ^ C120
18
10BK
PK
G103
i! 8W-15-5
C121
34 5 37 35 18 33 3 0 " ] CONTROLLER
ABS LEFT LEFT LEFT RIGHT RIGHT RIGHT ANTI-LOCK
PUMP FRONT FRONT FRONT FRONT FRONT FRONT BRAKE
MOTOR RESET ISOLATION DUMP RESET ISOLATION DUMP
RELAY SWITCH VALVE VALVE SWITCH VALVE VALVE
OUTPUT SENSE CONTROL CONTROL SENSE CONTROL CONTROL
8040d07b J968W-9
8W-35 ANTI-LOCK BRAKES BR
8W-35-10
A i S PUNP
MOTOR RELAY
(8W-35-6).
(8W-11-16)
HYDRAULIC
CONTROL UNIT CASE
I (8M-35-9) | GROUND
B120
t t i
B120 B120 B120
12BR 12BR 12BR 12BR
WT WT WT WT
B120 12BR/WT
B252 B254
18BR 16DG
TN OR
C121
34 19 28 26 CONTROLLER
ABS REAR REAR REAR ANTI-LOCK
PUMP VALVE ISOLATION DUMP BRAKE
MOTOR RESET VALVE VALVE
RELAY SWITCH CONTROL CONTROL
OUTPUT SENSE
«O40d07d J968W-9
BR 8W • 40 INSTRUMENT CLUSTER 8W - 40 -1
8W-40 I N S T R U M E N T CLUSTER
INDEX
page page
DESCRIPTION AND OPERATION MANUAL TRANSMISSION UP-SHIFT LAMP 3

ABS WARNING LAMP 2 OIL PRESSURE GAUGE 2
AIRBAG WARNING LAMP 3 OIL PRESSURE WARNING LAMP 2
ENGINE COOLANT TEMPERATURE GAUGE 1 PARKING BRAKE LAMP 3
FOUR-WHEEL DRIVE INDICATOR ........ 3 SEAT BELT INDICATOR WARNING LAMP . . . . . . 2
FUEL GAUGE . .• . 1 SERVICE REMINDER INDICATOR (SRI) LAMP . . 3
GENERATOR LAMP 3 SPEEDOMETER 1
HELPFUL INFORMATION 3 TACHOMETER 2
HIGH-BEAM INDICATOR LAMP 2 TURN SIGNAL INDICATOR LAMPS 2
INTRODUCTION .. 1 VOLTMETER 2
LOW FUEL WARNING LAMP . 2 SCHEMATICS AND DIAGRAMS
LOW WASHER FLUID LAMP .. 2 WIRING DIAGRAM INDEX 3
MALFUNCTION INDICATOR LAMP (MIL) 2
DESCRIPTION AND OPERATION gauge. The fuel level sensor draws voltage from cir
cuit F14 through the fuel gauge on circuit G4. The
INTRODUCTION fuel level sensor is located in the fuel tank.
The instrument cluster contains the . gauges., and As current flows through the coils in the fuel
warning lamps. A l l gauges have magnetic move gauge, i t creates a magnetic field. One of the coils in
ments. the gauge receives fixed current. The other coil is
When the' ignition switch is in the START or RUN connected to the level sensor. The magnetic field con
position, circuit A21 feeds circuit F14 through a bus trols the position of the fuel gauge pointer.
bar in the fuse block and fuse 12. Circuit A l from The fuel level sensor contains a variable resistor.
fuse 3 in the Power Distribution Center (PDC) sup As the position of the float arm on the fuel level sen
plies voltage to circuit A21. sor changes, the resistor changes the current flow
Circuit F14 provides battery voltage for the warn through the second coil in the fuel gauge. A change in
ing lamps (except seat belt indicator lamp), transmis current flow alters the magnetic field in the fuel
sion up shift lamp, and all gauges. gauge, which changes the pointer position.
Circuit E2 from fuse 13 in the fuse block feeds the Circuit Z l l provides the ground path for the fuel
illumination lamps. Circuit E l from the headlamp level sensor.
switch powers fuse 13 when the parking lamps or
headlamps are ON. ENGINE COOLANT TEMPERATURE GAUGE
Circuit Z3 provides ground for the indicator lamps Circuit G20 connects the engine coolant tempera
and illumination lamps. Circuit Z l l provides the ture gauge to the engine coolant temperature sensor.
ground path for the gauges. The sensor is a variable resistor and case grounded
to the engine on all engines except the 8.0L V-10.
SPEEDOMETER The V-10 engine coolant temperature sensor has an
The speedometer and odometer receive a signal external ground. Circuit F14 from fuse 12 in the fuse
from the Vehicle Speed Sensor (VSS) on circuit G7. block connects to the instrument cluster and supplies
Circuit G7 is spliced and also connects to the Power- voltage for the gauge.
train Control Module (PCM). As current flows through the coils in the gauge, it
Circuit F14 from the fuse block provides voltage for creates a magnetic field. One of the coils in the gauge
the speedometer. Circuit Z l l provides ground for the receives fixed current. The other coil is connected to
speedometer. the temperature gauge on circuit G20. A change in
temperature changes the resistance in the sensor,
FUEL GAUiE which alters the current flow through the second coil
Circuit G4 connects the fuel level sensor to the fuel in the gauge. A change in current flow alters the
gauge in the instrument cluster. Circuit F14 from magnetic field in the gauge, which changes the
fuse 12 in fuse block supplies voltage to the fuel pointer position.
8W - 40 - 2 8W - 40 INSTRUMENT CLUSTER BR
VOLTMETER IOWWASHER FLUID LAMP

Power for the voltmeter is supplied on circuit F14. Circuit G29 connects the low washer fluid switch
This circuit is spliced and supplies power to all the to the warning lamp in the instrument cluster. Cir
gauges. Ground for the voltmeter is supplied on cir cuit F14 supplies battery voltage to the lamp.
cuit Z l l . When the low washer fluid switch CLOSES, i t con
The F14 circuit is also used to measure the voltage nects circuits G29 and Z l . Circuit Z l provides a
level. The gauge reading changes based on the sys ground path, illuminating the warning lamp. Circuit
tem voltage in the F14 circuit. Z l also provides ground for the windshield washer
pump motor.
TACHOMETER
The tachometer module in the instrument cluster HIGH-BEAM INDICATOR LAMP
operates the tachometer. The Powertrain Control Circuit G34 supplies power for the high-beam indi
Module (PCM) supplies the signal for the tachometer cator lamp. The ground path for the lamp is through
on circuit G21. Circuit G21 connects to cavity C31 of circuit Z3. Circuit G34 splices to circuit L3. Circuit
the PCM. L3 feeds the high beam circuit of the headlamps.
OIL PRESSURE GAUIE TURN SIGNAL INDICATOR LAMPS

The case grounded oil pressure sensor is a variable Circuits L61 and L60 power for the turn signal
resistor that connects to circuits G60 and G6. Circuit indicator lamps. Circuit L61 powers the left indicator
G60 connects to the oil pressure gauge. Circuit G6 lamp. Circuit L60 powers the right indicator lamp.
connects to the oil pressure warning lamp. Circuit Z3 provides ground for the lamps.
Circuit F14 connects to the instrument cluster and
supplies battery voltage.to oil pressure gauge. 'The ABS WARNING LAMP
gauge uses two coils. One coil receives fixed current,
.circuit G60 connects the other coil to the pressure ALL-WHEEL ANTILOCK BRAKES
sensor. As oil pressure changes, the variable resistor The Controller, Antilock Brakes (CAB) provides
in the sensor changes the current flow through the ground for the ABS warning lamp i n the message
second coil i n the gauge. A change i n current flow center through the normally closed contacts in the
alters the position of the gauge pointer ABS warning lamp relay. When the ignition switch is
in the START position, the lamp illuminates as a
OIL PRESSURE WARNING LAMP bulb test for approximately 3 to 5 seconds while the
The case grounded oil pressure sensor is a variable CAB performs a system self-test. While closed, the
resistor that connects to circuits G60 and G6. Circuit relay contacts complete the ground path for the ABS
G60 connects to the oil pressure gauge. Circuit G6 warning lamp by connecting circuit G19 from the
connects to the oil pressure warning lamp. lamp to ground on circuit Z l . Power for the lamp is
Circuit F14 connects to the instrument cluster and supplied by circuit F14.
supplies battery voltage to oil pressure lamp. If the system self-test is successfully completed,
When the oil pressure is below a predetermined the CAB energizes the ABS warning lamp relay by
level the engine oil pressure, sensor completes a path providing ground for the. relay coil on circuit B47.
to ground causing the lamp to illuminate. When the relay energizes, its contacts open and dis
connect circuits G19 and Z l . Circuit A20 from fuse 14
LOW FUEL WARNING LAMP in the fuse block supplies power to the coil side of the
Circuit G4 connects the fuel level sensor to the low relay.
fuel relay i n the instrument cluster. When the fuel Circuit G19 from the ABS warning lamp splices to
level in the fuel tank reaches a calibrated level, the the CAB and the ABS warning lamp relay.
low fuel warning lamp relay illuminates the lamp.
REAR WHEEL ANTILOCK (RWAL) BRAKES
MALFUNCTION INDICATOR LAMP (MIL) The Controller Anti Lock Brake (CAB) provides
The Powertrain Control Module (PCM) provides ground for the instrument cluster Check Antilock
ground for the M I L on circuit G3. Circuit G3 con warning lamp on circuit G19. Circuit F14 provides
nects to cavity C17 of the PCM. When illuminated, voltage to the instrument cluster to feed the warning
the MIL displays the message CHECK ENGINE. For lamp.
information regarding diagnostic trouble code access
using the MIL, refer to Group 14, Fuel Systems. SEAT BELT INDICATOR WARNING LAMP
The seat belt indicator warning lamp is activated
by the buzzer module on circuit G13. Circuit G13
BR 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 3
supplies power to instrument cluster for the lamp. FOUR-WHEEL DRffE INDICATOR
Circuit Z3 provides ground for the lamp. Power for the four-wheel drive indicator lamp is
supplied on circuit F14. Ground for the lamp is sup
PARKING BRAKE LAMP plied on circuit G107 to the switch. The ground is
Power for the parking brake lamp is supplied on passed through the CLOSED contacts i n the switch
circuit F14. This circuit is protected by a 15 amp fuse to circuit Z l .
located in cavity 12 of the fuse block.
Ground for the lamp is supplied from two different GENERATOR LAMP
sources. One way is on circuit G i l . This circuit con Circuit F14 supplies power for the generator lamp.
nects from the lamp to the park brake switch located The lamp illuminates when the Powertrain Control
on the park brake mechanism. This switch is nor Module (PCM) provides ground for the lamp on cir
mally OPEN. When the switch CLOSES, a ground cuit G12. Circuit G12 connects to cavity C16 of the
path is completed through the case grounded switch. PCM.
On vehicles equipped with Daytime Running Lamps
(DRL), the G i l circuit is spliced and provides an SERVICE REMINDER INDICATOR (SRI) LAMP
input to the DRL module. Power for the SRI lamp is supplied on circuit F14.
The second ground path is supplied by the brake Ground for the lamp is controlled by the Powertrain
pressure warning switch. Circuit G9 connects from Control Module (PCM) on circuit G24. This circuit
the lamp i n the cluster to the switch. The switch is connects to cavity C16 of the PCM connector.
normally OPEN. When the brake pressure is below a
pre-determined pressure, the switch CLOSES and a HELPFUL INFORMATION
ground path is completed through the case grounded If the warning lamps don't operate, check fuse 12
switch. in the fuse block.
MANUAL TRANSMISSION UP-SHIFT LAMP

Circuit F14 supplies power for the manual trans SCHEMATICS AND DIAGRAMS
mission up-shift lamp. The lamp illuminates when
the Powertrain Control Module (PCM) provides WIRING DIAGRAM INDEX
ground for the lamp on circuit G54. Circuit G54 con The following index covers all components found i n
nects to cavity B l l of the PCM. this section of the wiring diagrams. I f the component
AIRBAG WARNING LAMP 8 W - 0 2 for a complete list of all components shown i n
Circuit F14 supplies power for the airbag warning the wiring diagrams.
lamp. The lamp illuminates when the Airbag Control
Module (ACM) provides ground for the lamp on cir
cuit R41.
8W - 40 - 4 8W-40 INSTRUMENT CLUSTER BR
DIAGRAM INDEX
Airbag Control Module 8W-40-12 Fuse 12 8W-40-5, 7, 8, 9,
Brake Switch 8W-40-7 Fuse 13 8W-40-10
Buzzer Module 8W-40-10 Fuse 18 8W-40-10
Controller Anti-Lock Brake 8W-40-7, 8, 9 Headlamp Switch 8W-40-10
Daytime Running Lamps Module 8W-40-8,11 Ignition Switch 8W-40-5, 7, 8,9,12
Engine Coolant Temperature Sending Unit 8W-40-6 Instrument Cluster 8W-40-5 thru 11
Engine Oil Pressure Sensor 8W-40-6 Joint Connector C 8W-40-7, 8,10
Four Wheel Drive (4WD) Switch 8W-40-9 Low Washer Fluid Switch 8W-40-12
Fuel Pump Module 8W-40-6 Park Brake Switch . . . 8W-40-8
Fuse 1 (PDC) 8W-40-10 Powertrain Control Module 8W-40-5, 7, 8,12
Fuse 3 (PDC) 8W-40-5. 7, 8, 9,12
8040d07e J968W-9
BR 8W-40 INSTRUMENT CLUSTER 8W - 40 - 5
BATTERY
POSITIVE AO 6RD-
TERMINAL
(8W-20-3.4)
AO POWER
RIGHT OOERD** DISTRIBUTION
BATTERY FUSE CENTER
POSITIVE 3
TERMINAL ENGINE 40A
(WITH D I E S E L SPLICE STARTER (3): C180
ENG) S148 MOTOR
CSM-20-4) (8W-70-21) (8W-2l-3,4)
Al
12RD
A21 12DB <( C133

1
Al 12RD-
VEHICLE POWERTRAIN
SPEED SENSOR CONTROL MODULE
(8W-30-14)
TACHOMETER
SIGNAL
G7 C31
18WT
OR
C137
S209 S131
F14 1 8 L G / Y L - 8W-70-30 8W-70-13
I
G7 G21
20WT 20GY
OR LB
S208
8W-70-30 ^ C127 sjs C127
F14 G7 G21
20LG 22WT 22GY
YL OR LB
^ C133 ^ C133
Zll Zll Zll G7 G21
18BK 20BK 20BK 20WT 22GY
WT WT WT OR LB
S210
8W-70-31
i
G7
20WT
OR
X
C215 C216 C215 C216 C215
0
(9) : (6): (8): (11) (3) •
_1
INSTRUMENT
CLUSTER
VOLT
^4
G202
8W-15-13
* WITH GAS ENG

** WITH DIESEL ENG
8040d080 J968W-9
8W-40-6- 8W-40 INSTRUMENT CLUSTER BR
ENGINE COOLANT
TEMPERATURE
SENDING UNIT
BLACK -BLACK
ENGINE OIL
PRESSURE
SENSOR
C139
CASE
FUEL LEVEL GROUND
SENSOR
(FUEL PUMP
MODULE)
C328 C128
» — Z l l 20BK/WT—(f-^
(4)
S116
8W-70-8
G6 G20
18GY** 18VT
YL
C127
C127 C127 C127 C128
660
G20 S140
22GY
YL G6 22VT G4 8W-70-18
22GY YL 20DB
CI33 C133 C133 C133
G119
8W-15-11,12
G60 G6 G20 G4
22GY 22GY 22VT 22DB
YL YL
Z3 20BK/0R
: C216
S206
8W-70-29
Z3
12BK
OR
G201
• I8W-15-13I
INSTRUMENT CLUSTER * WITH GAS ENG

* * WITH DIESEL ENG
8040CI082 J968W-9
BR- 8W-40 INSTRUMENT CLUSTER •8W-40- 7
BATTERY
POSITIVE
-AO 6RD
TERMINAL
(8W-20-3.4)
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH DIESEL
ENG)
(8W-20-4)
BLACK
CASE
= " GROUND
* WITH GAS ENG
* * WITH DIESEL ENG
8040d088 J968W-9
8H - 40 - 8 8W-40 INSTRUMENT CLUSTER
BATTERY
POSITIVE
AO 6RD-
TERMINAL
(8W-20-3,4)
POWER
RIGHT DISTRIBUTION
BATTERY FUSE CENTER
POSITIVE 3
TERMINAL ENGINE 40A
(WITH DIESEL SPLICE STARTER (3): C180
ENG) S148 MOTOR
C8W-20-4) (8W-70-21) (8W-2I-3,4)
Al
] IGNITION
ACC 12RD
SWITCH
S124
OFF
C2I2 8W-70-12 CI33 CONTROLLER
C212 -Al 12RD-4 •Al 12RD J
ANTI-LOCK
RUN
A 2 1 12DB- BRAKE
(7)
(RWAL)
(2)
START PARK
DAYTIME
C131 PARK BRAKE
BRAKE RUNNING
SWITCH
POWERTRAIH SWITCH LAMP SENSE
MALFUNCTION SENSE MODULE 5
CONTROL Gil
INDICATOR MODULE 20WT
LAMP DRIVER C228
BK
C17
3g C 1 3 7 C133
G3 Gil Gil
20BK 22WT 22WT
PK BK BK
4? C126 (11) (9) 4 C209

G3 JOINT
• 8W-70-30 22BK CONNECTOR C
PK
JOINT _ J
CONNECTOR C (10): (8): C209
C133 C8W-40-7)
(8W-12-10) Gil
20WT
BK
F14
20LG
YL
G3
22BK
PK
G9
22GY
BK
A- BLACK
(8): (6): C215 (4): C216

INSTRUMENT PARK
LAMP
CLUSTER BRAKE
CHECK
SWITCH
MIL C216
(CHECK
ENGINE) BRAKE -Gil 22WT/BK-
CASE
(5) GROUND
* WITH GAS ENG

** WITH DIESEL ENG
8040d08a J968W-9
1
BR 8W-4Q INSTRUMENT CLUSTER 8W - 40 - 9
BATTERY
POSITIVE
-AO 6RD
TERMINAL
(8W-20-3.4)
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH D I E S E L
ENG)
C8W-20-4)
* WITH GAS ENG

8040d08c J968W-9
8W-40-10- 8W-40 INSTRUMENT CLUSTER BR
POWER
BATTERY FUSE 1 £ i M DISTRIBUTION•
POSITIVE CENTER
AO 6RD
TERMINA
50A )
C8W-2Q-3. a
A7
10RD
BK
S147 I
8W-70-21
RIGHT AO
BATTERY OOERD**
POSITIVE
TERMINAL » A7
(WITH DIESEL SPLICE ENGINE 12RD
ENG) S148 STARTER BK
(8W-20-4) C8W-70-21) MOTOR
<8W-21-3 4) P
R E F TO
OVERDRIVE
-A7 12RD/BK
SWITCH
ILLUMINATION
C133
S204
A7 12RD/BK (8W-31-7)
WITH FOG LAMPS
E2 220R—-
E2
200R
BUZZER
SEAT BELT J MODULE
I LAMP DRIVER ,
E2 l _ J
220R ^ C218
G13 2 0 D B / R D -
(1): C215 (1) C216

INSTRUMENT
GENERAL ILLUMINATION CLUSTER
© (Q) (Q) Q © © 1 « T © ~
C216 —• -A # m A ^ I 1 LAMP
— < f
Z3
(10) 1
j
S206
20BK
OR 8W-70-29 G201
•13 12BK/0R- 11 8W-15-13 *

**
WITH GAS ENG
WITH DIESEL ENG
8040d08e J968W-9
8W-40 INSTRUMENT CLUSTER 8W-40-11
DAYTIME RUNNING
LAMP MODULE
HIGH BEAM
INDICATOR
LAMP HEADLAMP
DRIVER •L3 16RD/0R-
DIMMER
4 SWITCH
(8W-50-4)
• C131 €133
G34 L3
18RD 16RD
GY OR
S1S3 S121
8W-70-23 8W-70-10
G34 G34
18RD 18RD
GY GY
C133 C133
G34 634
18RD 18RD
WITH
TURN SIGNAL/ GY GY
DRL
HAZARD SWITCH
(8W-50-5)
(8W-52-5) S206
8W-70-29
L61 L60 634 Z3 Z3

20LG 20TN 18RD 20BK 12BK
YL BK GY OR OR
G201
8W-15-13
(12) : (14) : (13) (10)- C216

INSTRUMENT
CLUSTER
LEFT RIGHT HIGH
TURN TURN BEAM
• SIGNAL SIGNAL IND
IND IND
8040d090 J968W-9
8W-40-12 8W-40 INSTRUMENT CLUSTER BR
BATTERY
POSITIVE
-AO 6RD
TERMINAL
<8W-20-3,4)
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH DIESEL
ENG)
(8W-20-4)
G29
22BK 18BK
TN TN
(8): C215 (3): C216 (5) (7): C215 (9) : C216

INSTRUMENT
CLUSTER
-vQj -vQj
UPSHIFT MAI NT LOW AIRBAG SPARE

REQ WASHER
* WITH GAS ENG

** WITH DIESEL ENG
8040d092 , . — -j J968W-9
BR 8W - 41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1
8 W - 4 1 HORN/CIGAR LIGHTER/POWER O U T L E T
DESCRIPTION AND OPERATION When the operator presses the lighter, contacts
inside of the lighter element CLOSE and voltage
HORN flows through the heating element to ground on cir
The horn system is powered by a 20 amp fuse cuit Z3.
located in the Power Distribution Center (PDC), cav
HELPFUL INFORMATION
ity B, which is HOT at all times on circuit F31. This
• Circuit F30 also supplies power to the power
circuit supplies voltage to the coil and contact side of
outlet.
the horn relay.
• Check the 40 amp fuse located in cavity 3 of the
When the operator presses the horn switch, a
PDC
ground path is completed on the coil side of the horn
relay through the switch. The horn relay, located in
fuse block
the PDC, then CLOSES the relay contacts. Voltage is
• Check the cigar lighter element
passed through the CLOSED relay contacts on circuit
X2 to the horns. POWER OUTLET
HELPFUL INFORMATION Fuse 1 in the fuse block feeds the power outlet on
• Check the 20 amp fuse located in cavity B of the circuit F130. Circuit F130 is HOT at all times. Cir
PDC. cuit Z3 supplies ground for the power outlet.
• Press the horn switch and listen for the horn
relay to click. A clicking relay indicates voltage is
present up to the switch.
CIGAR LIGHTER
When the ignition switch is i n the ACCESSORY or The following index covers all components found in
RUN position, i t connects circuit A l from fuse 3 in this section of the wiring diagrams. I f the component
the Power Distribution Center (PDC) to circuit A31. you are looking for is not found here, refer to section
Circuit A31 powers circuit F30 through fuse 5 in the 8W-02 for a complete list of all components shown in
fuse block. Circuit F30 supplies current to the cigar the wiring diagrams.
lighter.
8W - 41 - 2 8W-41 HORN/CIGAR LIGHTER BR
DIAGRAM INDEX
Cigar Lighter 8W-41-3 Horn Relay 8W-41-4
Fusel (PDC) 8W-41-4 Horns 8W-41-4
Fuse 3 (PDC) 8W-41-3 Ignition Switch 8W-41-3
Fuse 5 8W-41-3 Power Outlet 8W-41-3
Fuse B 8W-41-4 Vehicle Speed Control/Horn Switch 8W-41-4
Ground Joint 8W-41-4
8040d094 J968W-9
BR 8W-41 HORN/CIGAR LIGHTER 8W -41-3
AO 6RD
BATTERY
POSITIVE
TERMINAL
(8W-20-3,4)
AO
20BK*
RIGHT
BATTERY
POSITIVE AO
TERMINAL 14PK**
(WITH
DIESEL ENG)
(8W-20-4)
ENGINE SPLICE
STARTER S148
MOTOR (8W-70-21)
(8W-21-3.4)
• Al 12RD-
FUSE
(45) C241 BLOCK
FUSE
1
20A
(49):
C241
"1 FUSE
BLOCK
F130
18RD C241 FUSE 5 ft C241
YL —A31 12BK/WT
(41) 20A 1 (39)
-F30 18RD/0R
(1) : C235
FUSED POWER
IGN OUTLET
SW S215
OUTPUT 8W-70-33
(ACC/RUN)
€235
GND -» -Z3 18BK/0R- •Z3 18BK/0R
(2)
Z3
12BK
OR
G202
8W-15-13
* WITH GAS ENG
* * WITH DIESEL ENG
8040(1095 J968W-9
8W - 41 - 4 8W-41 HORN/CIGAR LIGHTER BR
BATTERY
POSITIVE
TERMINAL
(8W-20-3.4)
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH
DIESEL ENG)
C8W-20-4)
ENGINE SPLICE
STARTER S148
MOTOR <®W70-21)
(8W-21-3.4)
POWER
C180 FUSE B C180
DISTRIBUTION
• F 3 1 18VT- CENTER
S155
(B2) 20A (Bl) i 50A
8W-70-24
(1) ^ C18Q
A7 A7
12RD 10RD
BK BK
S147
8W-70-21
X2 18DG/RD - HIGH
X2 18DG/RD - LOW ® NOTE

HORN
NOTE
© HORN
Zl
X3
22BK 18BK
RD
•Zl 18BK-
(1) CI23
C133 GROUND
GND
GND JOINT
X3
20BK
RD
X3
22BK
RD
WITH POWER
WINDOWS AND
POWER LOCKS
(4)
? C123
WITH MEDIUM-
LINE AND
Zl Zl HIGH-LINE
14BK 12BK CLUSTER
VEHICLE SPEED G1Q1
CONTROL/ 8W-15-3
HORN S W I T C H S108
•Zl 12BK-
C203 r 8W-70-5
wmSmm I
(b) ! t: nn CASE *
**
WITH GAS ENG
WITH DIESEL ENG
GROUND
8040d097 J968W-9
BR 8W - 42 AIR CONDITIONING/HEATER 8W - 42 - 1
8W-42 A I R CONDITIONING/HEATER
INDEX
page page
GENERAL INFORMATION BLOWER MOTOR .• 1

INTRODUCTION . . . . . . . . . . . . . HELPFUL INFORMATION . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION AND OPERATION SCHEMATICS AND DIAGRAMS
AIR CONDITIONING OPERATION WIRING DIAGRAM INDEX 2
G E N E R A L INFORMATION resistor block consists of three resistors connected in

series.
INTRODUCTION Each resistor in blower motor resistor block is
This section of the wiring diagrams covers the spliced to the fan switch on separate circuits; C4, C5,
operation of the Heater only and the Heater-A/C sys C6, and C7. Depending on fan switch position, volt
tems. age passes through one or more resistors to ground.
Several fuses supply power for the A/C-Heatef sys Blower motor fan speed is controlled by the number
tem. Fuse B, a 20 amp, from the Power Distribution of resistors voltage passes through to ground.
Center (PDC) supplies battery voltage on circuit F31 When the fan switch is in the LOW position, cir
to the contact side of the A/C compressor clutch relay. cuit C4 provides the ground path. In the M l position,
Circuit F31 is HOT at all times. circuit C5 provides ground. In the M2 position, the
In the START or RUN position, the ignition switch ground path is through circuit C6. Circuit C7 pro
connects circuit A l from fuse 3 in the PDC to circuit vides path for ground when the switch is in the
A21. Circuit A21 feeds fuse 9, a 10 amp, in the fuse HIGH position.
block. Circuit F18 connects from fuse 9 to the coil
side of the A/C compressor clutch relay AIR CONDITIONING OPERATION
In the RUN position only, the ignition switch con When the A/C-Heater control switch is moved to an
nects circuit A2 from fuse 2, a 40 amp, in the PDC to A/C position or the defrost position, the Powertrain
circuit A22. Circuit A22 supplies voltage to a bus bar Control Module (PCM) receives the A/C select signal
in the fuse block. Fuse 2, a 4 amp, connects to the on circuit C90. Circuit C90 connects to PCM cavity
bus bar and protects circuit C l which feeds the C23. I f the A/C low pressure and high pressure
blower motor. switches are CLOSED, the Powertrain Control Mod
Circuit E2 from fuse 13 in the fuse block powers ule (PCM) receives the A/C request signal on circuit
the illumination lamps in the A/C heater control C20. Circuit C20 connects to cavity C22 of the PCM.
switch. After receiving the A/C request signal, the PCM
supplies ground for the coil side of the A/C clutch
relay on circuit C13. Circuit C13 connects to cavity
DESCRIPTION AND OPERATION C l of the PCM. Circuit F18 supplies battery voltage
to the coil side of the relay. Circuit F31 from fuse B
BLOWER MOTOR in the Power Distribution Center (PDC) supplies
When the ignition switch is in the RUN position, voltage to the contact side of the relay.
circuit A2 from fuse 2, a 40 amp, in the Power Dis When the PCM grounds the A/C compressor clutch
tribution Center (PDC) connects with circuit A22. relay, the contacts CLOSE and connect circuits F31
Circuit A22 supplies voltage to a bus bar in the fuse and 03. Circuit C3 supplies voltage to the A/C com
block that powers fuse F2. Fuse F2 protects circuit pressor clutch. Ground for the compressor clutch is
C l which supplies battery voltage to the blower provided on circuit Z l l .
motor. The A/C compressor clutch connector has a built-in
From the blower motor, circuit C7 splices to the diode. The diode controls the induced voltage that
blower motor resistor and the A/C-Heater control results from the magnetic field collapsing when the
switch. clutch disengages. The diode provides a current path
The ground path for the blower motor is through to protect other components and systems.
the circuits that connect from the blower motor resis
tor block and then through the fan switch in the A/C
heater controls to circuit - Z3. The blower motor
8W - 42 - 2 8W - 42 AIR CONDITIONING/HEATER BR
HELPFUL INFORMATION you are looking for is not found here, refer to section
• Check the 40 amp fuses located in cavities 2, 8W-02 for a complete list of all components shown in
and 3 of the PDC the wiring diagrams.
• Check the 30 amp fuse located in cavity F2 of
the fuse block
fuse block

BR • • 8W-42 AIR CONDITIONING/HEATER 8W - 42 - 3
DIAGRAM 1NDE1
A/C Compressor Clutch 8W-42-8 Fuse 9 8W-42-8
A/C Compressor Clutch R e l a y . . . . . . . . . . . . . . . . . . . 8W-42-8 Fuse 1 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-7
A/C High Pressure Cutout Switch 8W-42-6 Fuse 18 8W-42-7
A/C Low Pressure Cutout Switch . . . . . . . . . . . . . . . . . 8W-42-6 Fuse B 8W-42-8
A/C-Heater Control Switch 8W-42-6 Headlamp Switch SW-42-7
Blower Motor 8W-42-4, 5 Heater Controi Switch 8W-42-4
Blower Motor Resistor Block 8W-42-4, 5 Ignition Switch 8W-42-4, 5, 8
F2 8W-42-4, 5 Joint Connector A 8W-42-7
Fusel (PDC) 8W-42-7,8 Joint Connector C 8W-42-7
Fuse 2 (PDC) 8W-42-4, 5 Powertrain Control Module 8W-42-6, 8
Fuse 3 (PDC) 8W-42-8
8040d099 J968W-9
8W-42-4* 8W-42 AIR CONDITIONING/HEATER 1
BR
(HEATER OILY)
SPLICE
AO 14PK** S148
BATTERY ENGINE C8W-70-21)
POSITIVE STARTER
TERMINAL MOTOR
<8W-20-3,4) (8W-21-3.4)
POWER
DISTRIBUTION
RIGHT CENTER
BATTERY
POSITIVE
TERMINAL
(WITH
D I E S E L ENG)
C8M-20-4)
J
( 4 ) xS C212
FUSE ACC
IGNITION
S201 BLOCK SWITCH
C241 FUSE F2 C241 8W-70-26 C212 ! OFF/ P
#—O^r* )) A22 1 2 B K / 0 R - -A22 •
12BK/0R- «4 >
(12) 30A (ID (5) ]
• START
HEATER
JOINT
CONNECTOR C
(8W-42-6)
(8W-12-6)
* WITH GAS ENG

8040d09b J968W-9
BR 8W-42 AIR CONDITIONING/HEATER 8W - 42 - 5
SPLICE
-AO 20BK*- AO 1 4 P K * * S148
BATTERY (8W-70-21)
POSITIVE
TERMINAL
(8W-20-3.4)
RIGHT
JATTERY
POSITIVE
TERMINAL
(WITH
DIESEL ENG)
C8W-20-4)
A/C-HEATER
CONTROL
SWITCH
(8W-42-6)
* WITH GAS ENG

** WITH DIESEL ENG
8040d09c J968W-9
8W-42-6- 8W-42 All CONDITIONING/HEATER BR
POWERTRAIN
C137 i CONTROL
A/C A/C
BLOWER C90 1 8 L G — « - j C 2 3 SELECT MODULE
MOTOR
r
REQUEST
INPUT
C8W-42-S) C22
S160
8W-70-26 ^ C137
C90
C20
C90 18LG
18BR
18LG
(1): C165 (1) 4* C185
C7 A/C A/C
12BK C125 HIGH LOW
TN
\ PRESSURE
CUTOUT
SWITCH
PRESSURE
CUTOUT
SWITCH
C90 (2) : C165 (2): C182

18LG
L90 18LG/WT-
$217
8W-70-34
C22J A/C
C7 12BK/TN 1<f 1 FAN HEATER
:(6) H2
HIGH* S W I T C H CONTROL
SWITCH
|(5)
Ml
C133
-Kf-
(3)
LOW f
(4)
DEF
1 HEAT
1 HI/
C90
C7 C6 ' C5 C4 a LO 22LG
12BK 14LB 16LG 16TN I #A/C
TN YL
OFF MAX
JOINT
DEF
CONNECTOR C
C8W-42-7)
C227 (8W-12-6)
(2)!
C237
E2
220R
C7 C6 C5 C4
12BK
14LB 16LG 16TN
TN
(1)
ILLUMINATION S215
8W-70-33 G202
Z3 Z3
-12BK- -12BK 8W-15-13
OR OR
BLOWER MOTOR RESISTOR BLOCK.
<8W 4 2 5 )
(7) C227
Y
* WITH GAS ENG

8040d09f J968W-9
BR ^ — 8W-42 AIR CONDITIONING/HEATER — 8W - 42 - 7
SPLICE
AO 1 4 P K * * - S148
POSITIVE ^ STARTER
TERMINAL AO OOERD**-
MOTOR
(8W-20-3,4) (8W-21-3.4)
POWER
S147 DISTRIBUTION
RIGHT C180 8W-70-21 CENTER
BATTERY ! I FUSE 1
POSITIVE - » A7 10RD/BK — # 1
TERMINAL 50A (1)
(WITH
DIESEL ENG) WITH
(8W-20-4) POWER
S E A T
S204
HEATER 8W-70-28
CONTROL
SWITCH -A7 12RD/BK
I
(8W-42-4) A7
OR 12RD
A/C-HEATER BK
CONTROL
SWITCH
(8W-42-6)
OVERDRIVE
SWITCH
ILLUMINATION E2 200R
WITH
LAMP FOG
(8W-31-7) LAMPS
FOG LAMP * WITH GAS ENG
E2 2 2 0 R - - SWITCH ** WITH DIESEL ENG
(8W-50-10)
8040d0ae J968W-9
8W - 42 - § • 8W-42 AIR CONDITIONING/HEATER BR
SPLICE
AO 14PK**- S148
BATTERY (8W-70-21)
ENGINE
POSITIVE
^ STARTER
TERMINAL AO OOERD**
MOTOR
C8W-20-3„4) (8W-21-3,4)
AO 6RD-
^ RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH
DIESEL ENG)
(8W-20-4)
- POWER
DISTRIBUTION
CI80 FUSE B C1SQ
CENTER
- F 3 1 18VT- ——)>
S15S (B2) 20A (Bl)
8W-70-24
A7
12RD (1) : (3): C180
BK
A7
(30) C180 10RD
A/C Al
BK
12RD
COMPRESSOR
S147
CLUTCH
8W-70-21
RELAY C133
F18
20LG
C180 BK
Al
12RD
C3 C13
18DB 22DB C133
F18
BK OR • —20LG » -j
B K
S114 F18
t
C3
C126
C125
8W-70-7
22LG
BK
(33) ^ C241 BLOCK

18DB
BK
FUSE
(1) C164 9
A/C C13 10A
M% COMPRESSOR 20DB
I
CLUTCH OR
(31)N^ £241
(2) C164
C137
POWERTRAIN
Cl
A / C CMP CONTROL
CLUTCH MODULE
Zll RELAY
18BK CONTROL
WT
S140 G119 - A 2 1 12DB

8W-70-18 8W-15-11,12
Zll
-16BK-
WT
1 *
**
WITH GAS ENG
WITH DIESEL ENG
8040d0b0 J968W-9
BR 8W - 43 AIRBAG SYSTEM 8W - 43 - 1
8W-43 AIRBAG SYSTEM
DESCRIPTION AND OPERATION From the right impact sensor, Circuit R46 connects
to the ACM at cavity 13 of the 13 way connector. Cir
AIRBAG CONTROL MODULE (ACM) cuit R48 connects to cavity 12 of the 13 way connec
Two circuits provide battery voltage to the Airbag tor.
Control Module (ACM); F14 and F23. Circuits F14
and F23 are connected to separate bus bars in the AIR1AG SQUIB (AIRBAG IGNITER)
fuse block. Different circuits from the Power Distri Two circuits, R43 and R45, connect the ACM to the
bution Center (PDC) and the ignition switch supply driver's side airbag squib (igniter) after passing
battery voltage to the fuse block bus bars. through the clock spring connector. Circuit R43 con
Circuit F23 supplies battery voltage to the ACM nects to cavity 3 of the ACM 4 way connector; circuit
only when the ignition switch is in the RUN position. R45 connects to cavity 4 of the ACM 4 way connector.
Circuit F14 powers the ACM when the ignition R43 and R45 are a twisted pair of wires.
switch is in either the START or RUN position.
In either the START or RUN position, the ignition AIRBAG WARNING LAMP
switch connects circuit A l from fuse 3 i n the PDC Circuit R41 connects the airbag warning lamp to
with circuit A21. Circuit A21 circuit supplies battery cavity 7 of the ACM 13 way connector. The airbag
voltage to the fuse block bus bar that feeds circuit warning lamp is part of the instrument cluster. Refer
F14. Fuse 12, a 15 amp, in the fuse block protects to section 8W-40, Instrument Cluster.
circuit F14.
When the ignition switch is in the RUN position, i t DATA LINK CONNECTOR
connects circuit A2 from fuse 2, a 40 amp, in the The DRB scan tool connects to the data link con
PDC to circuit A22. Circuit A22 supplies battery volt nector. A twisted pair of wires, circuits D l and D2,
age to the fuse block bus bar that feeds circuit F23. send and transmit data between the ACM and the
Fuse 16, a 15 amp, in the fuse block protects circuit DRB scan tool.
F23.
The ACM is case grounded and has an external
dedicated ground, circuit Z6.
AIRBAG IMPACT SE1S0RS
Two airbag impact sensors provide input to the Air-
bag Control Module (ACM). Each sensor has two cir
cuits that connect to the ACM.
From the left impact sensor, Circuit R47 connects
to the ACM at cavity 6 of the 13 way connector. Cir
cuit R49 connects to cavity 5 of the 13 way connector.
8W - 43 - 2 — • 8W-43 AIR SYSTEM — BR
iJAIRAi INDEX
Airbag Control Module 8W-43-3,4 Fuse 1 6 . . . . . . . . . . . . . . 8W-43-3
Data Link Connector .8W-43-4 Ignition Switch ... ... .8W-43-3
Driver Side Airbag 8W-43-4 Instrument C l u s t e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-4
Fuse 2 (PDC) 8W-43-3 Left Airbag Sensor 8W-43-4
Fuse 3 (PDC) 8W-43-3 Right Airbag Sensor. 8W-43-4
Fuse 12 8W-43-3
8040d0bl J968W-9
BR 8W-43 AIRBAG SYSTEM 8W- 4 3 - 3
BATTERY
POSITIVE •AO 6RD
TERMINAL
(8W-20-3,4)
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH DIESEL
ENG)
(8W-20-4)
F23 F14 S209

18DB 18LG
8W-70-30
YL YL
H=HHfc8«hf¥fc-
C232
AIRBAG
2 1
FUSED CONTROL
FUSED
IGN SW IGN SW MODULE
OUTPUT OUTPUT
(RUN) (START/RUN)
GND
11
^ C232
C133
L_ Z6 18BK/0R-
G108
8W-15-9
•16 18BK/0R
*WITH GAS ENG
* * W I T H DIESEL ENG
8040d0b3 J968W-9
8W - 4 3 - 4 - 8W-43 AIRBAG SYSTEM BR
DRIVER SIDE AIRBAG
( - ) > — R43 20BK—<£- - » — -R43 18BK/LB-

AIRBAG CLOCK-
SQUIB
IGNITER SPRING
j-»—R45 20DG—<£- -R45 18DG/LB-
"» TWISTED
PAIR
C20S
TWISTED
PAIR
R45 R43
18DG 18BK
LB LB
C233
4 3
] AIRBAG
AIRBAG AIRBAG CONTROL
LINE 2 LINE 1 NODULE
AIRBAG
SYSTEM
CCD BUS CCD BUS WARN LAMP I T IMPACT LT IMPACT RT IMPACT RT IMPACT
(+) (-) DRIVER SENSOR LINE 2 SENSOR L I N E 1 SENSOR LINE 2 SENSOR L I N E 1
3 4 7 5 6 12 . 13 ;
C232
Dl D2 R41 R49 R47 R48 R46

18VT 18WT 18BK 18LB 18DB 18TN 18BR
BR BK TN LB LB
(9): C218 C133 C133

AIRBAG
SYSTEM
WARN
LAMP R49 R47 R48 R46
DRIVER 18LB 18DB 18TN 18BR
J
WT LB LB
INSTRUMENT
CLUSTER
(11) C223 (1): (2): CllO (1>* (2)^ f C103
DATA LINK LT IMPACT LT IMPACT
LEFT RT IMPACT RT IMPACT RIGHT
CONNECTOR SENSOR SENSOR AIRBAG SENSOR SENSOR AIRBAG
LINE LINE SENSOR LINE LINE SENSOR
2 1 1
I * J
,; ; :. d
8040d0b5 J968W-9
8W - 44 INTERIOR LIGHTING 8W - 44 -1
8W-44 I N T E R I O R L I G H T I N G
INDEX
page page
DESCRIPTION AND OPERATION KEY-IN-SWITCH HALO LAMP . . . . . . . . . . . . . . . . 1

BUZZER MODULE 2 SEAT BELT SWITCH . .. 2
CARGO LAMPS 2 TIME DELAY RELAY 1
DAY/NIGHT MIRROR 1 UNDERHOOD LAMP 1
DOME LAMP 1 VISOR/VANITY LAMPS 2
GLOVE BOX LAMP 1 SCHEMATICS AND DIAGRAMS
HELPFUL INFORMATION 2 WIRING DIAGRAM INDEX . . 2
INTRODUCTION 1
DESCRIPTION A N D OPERATION 1L0¥E 101 LAiP

Circuit M l from the IOD fuse (fuse 17) in the fuse
INTRODUCTION block powers the glove box lamp. A switch, in series
Circuit M l supplies power to the underhood lamp, after the lamp, CLOSES when the glove box door is
glove box lamp, dome lamp, buzzer module, cargo OPENED. The switch completes a path to ground on
lamps, vanity lamps and the time delay relay. Circuit circuit Z3.
M50 from the time delay relay powers the ignition
switch lamp. UNDERHOOD LAMP
Circuit M l is protected by the Ignition Off Draw Circuit M l from the IOD fuse (fuse 17) in the fuse
(IOD) fuse i n the fuse block, cavity 17. This fuse is a block supplies battery voltage for the underhood
15 amp. lamp. A mercury switch, in series after the lamp, con
Power for the M l fuse is supplied on circuit A7. nects the lamp to ground on circuit Z l . When the
This circuit originates i n the Power Distribution Cen hood is raised, mercury inside the switch moves to a
ter (PDC) and is protected by a 50 amp fuse located position where it connects circuit M l to ground cir
in cavity 1. cuit Z l , illuminating the lamp.
KEY-IN-SWITCH HALO LAMP DOME LAMP"

Circuit M50 from the time delay relay supplies Circuit M l from the IOD fuse (fuse 17) in the fuse
voltage to the key-in-switch halo lamp. Circuit Z3 block supplies power to the dome lamp. This circuit
provides ground for the lamp. is HOT at all times. The ground path for the lamp is
Circuit M l supplies voltage to the time delay relay. provided in two different ways.
Circuit M2 provides ground for the relay through the One way is through the door jamb switches. Circuit
headlamp switch or the door jamb switch. M2 connects to the door jamb switches from the
dome lamp. The switches * are connected to ground
TIME DELAY RELAY circuit Z3. When a door is OPENED, the switch
The time delay relay is used to allow a time-ON CLOSES, completing a path to ground on circuit Z3.
function for the ignition switch lamp. Power for the The second ground path is through the headlamp
relay is provided on the M l circuit from the IOD fuse switch. Circuit M2 is spliced in with the headlamp
(fuse 17) in the fuse block. switch. When the operator turns the headlamp
Circuit M2 provides ground for the time delay switch to the dome lamp ON position, a ground path
relay through the right and left door jamb switches is provided through the switch on circuit Z3.
and the headlamp switch. When a door is OPENED,
or the headlamp switch is moved to the dome/cargo DAY/NIGHT MIRROR
lamp ON position, a ground path is provided for the The day/night mirror receives power from circuit
relay on circuit M2. This energizes the relay, causing L10 when the ignition switch is i n the RUN position.
the contacts to CLOSE. This circuit is protected by a 10 amp fuse located i n
When the relay contacts CLOSE, power is provided cavity 15 of the fuse block. Circuit Z4 provides
through the relay to circuit M50. The M50 circuit ground for the day/night mirror.
supplies current to the key-in-switch halo lamp. Cir When the back-up lamps switch CLOSES, circuit
cuit Z3 provides ground for the lamp. L I provides a signal to the day/night mirror. The day
8W - 44 - 2 8W - 44 INTERIOR LIGHTING
night mirror turns OFF when the vehicle is in fuse is the Ignition-Off Draw fuse (IOD) and is HOT
reverse. at all times. Power for the fuse is supplied on circuit
A7. This circuit is protected by a 50 amp fuse located
VISOR/VANITY LAMPS in cavity 1 of the Power Distribution Center (PDC).
Power for the visor/vanity lamps is supplied on When the parking lamps or headlamps are ON, the
Circuit M l . This is the Ignition-Off Draw (IOD) cir headlamp switch connects circuit G16 from the driv
cuit and is protected by a 15 amp fuse located in cav ers side door jamb switch to circuit G26. Circuit G26
ity 17 of the fuse block. Power for the fuse is connects to the buzzer module and the key-in switch.
supplied on circuit A7. Circuit G16 from the drivers side door jamb switch
When the operator lifts the cover, a switch internal also connects to the key-in switch.
to the lamp CLOSES connecting the lamp to circuit Circuit G13 from the buzzer module powers the
Z4 illuminating the lamp. The Z4 circuit is the seat belt warning lamp in the instrument cluster.
ground circuit. Circuit Z3 at the instrument cluster provides ground
for the lamp.
CARGO LAMPS Circuit G10 from the buzzer module connects to
Circuit M l from the IOD fuse (fuse 17) in the fuse the seat belt switch. When the seat belt switch
block supplies power to the cargo lamps. This circuit CLOSES a path to ground is completed on circuit Z3.
is HOT at all times. The ground path for the lamp is Circuit Z3 also grounds the buzzer module.
provided on circuits M3 and Z3.
When the operator turns the cargo lamps ON, cir HELPFUL INFORMATION
cuit M3 connects * from the lamps to the headlamp • Check the 15 amp fuse in cavity 17 of the fuse
switch. The ground path passes through the switch block
to circuit Z3. • Check the 50 amp fuse located in cavity 1 of the
PDC
SEAT BELT SWITCH • Check the door jamb switches for a good ground
For operation of the seat belt switch refer to the • Check the lamp filaments
circuit descriptions for the buzzer module in this sec • For the day/night mirror, check the back-up
tion. lamp switch, the 10 amp fuse in cavity 15 of the fuse
block, and the 40 amp fuse in cavity 2 of the PDC
BUZZER MODULE
The buzzer module sounds an audible warning
tone. The tone sounds for seat belt warning, when SCHEMATICS AND DIAGRAMS
the ignition key is in the ignition switch while the
drivers door is OPEN, or the headlamps are left ON WIRING DIAGRAM INDEX
with the drivers door open. The tone also sounds The following index covers all components found i n
when the ignition key is in the ON position while the this section of the wiring diagrams. I f the component
drivers side seat belt is not buckled. Refer to Group you are looking for is not found here, refer to section
8U for buzzer module operation. 8W-02 for a complete list of all components shown i n
Power for the buzzer module is supplied on circuit the wiring diagrams.
M l from fuse 17, a 15 amp, in the fuse block. This
BR 8W-44 INTERIOR LIGHTING 8W-44-3
DIAGRAM INDEX
Buzzer Module 8W-44-7 Headlamp Switch 8W-44-5, 7
Cargo Lamps 8W-44-5 Ignition Switch 8W-44-6, 9
Day/Night Mirror 8W-44-9 Instrument Cluster 8W-44-7
Dome Lamp 8W-44-5 Joint Connector A 8W-44-5
Fuse 1 (PDC) 8W-44-4, 7, 8 Joint Connector B 8W-44-8
Fuse 2 (PDC) 8W-44-9 Joint Connector C 8W-44-6, 9
Fuse 3 (PDC) 8W-44-6 Key-ln-Switch/Halo Lamp 8W-44-5, 7
Fuse 11 8W-44-6 Seat Belt Switch 8W-44-7
Fuse 15 8W-44-9 Time Delay Relay 8W-44-4, 5
Fuse 17 8W-44-4, 7, 8 Underhood Lamp 8W-44-8
Glove Box Lamp/Switch 8W-44-8 Visor/Vanity Lamps 8W-44-4
8040d0b7 J968W-9
8W - 44 - 4 8W-44 INTERIOR LIGHTING mm
POWER
BATTERY
POSITIVE
TERMINAL
(8W-20-3.4)
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH DIESEL
ENG)
C8W-20-4)
DOME LAMP * WITH GAS ENG

C8W-44-5) ** WITH DIESEL ENG
8040d0b9 J968W-9
B B - - -- - — - 8W-44 INTERIOR LIGHTING _ 8W - 44 - 5
FUSE
BLOCK
(8W-44-4)
C8W iQ 1 0 )
FUSE BLOCK
JOINT CONNECTOR A
8040d0ba J968W-9
8W - 44 - 6 8W-44 INTERIOR LIGHTING
POWER
DISTRIBUTION
BATTERY FUSE 3 C 1 8 0 CENTER
POSITIVE
TERMINAL
40A (3)
(8W-20-3 4)P
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH DIESEL
ENG) SPLICE . ENGINE
(8W-20-4) S148 STARTER
(8W-70-21) MOTOR
C8W-21-3.4)
OVERDRIVE
SWITCH
(8W-31-7)
4
FUSE
C241 F U S E ii C241 BLOCK
-(( m-s\j~~m ))- - A 2 1 12DB
F12 (35) 10A (31)
22DB
L E F T DOOR
WT
G16 1 8 B K / L B - JAMB SWITCH
F12 C8W-49-4)
22DB
WT G16
22BK
LB
(14) (12) (20) C209

JOINT
CONNECTOR
C
(13) : (22) (21) C209
F12 G16 G16

20DB 22BK 22BK
WT LB LB
BUZZER • KEY-IN- HEADLAMP

MODULE SWITCH/ SWITCH
C8W-44-7) " HALO LAMP ' (8W-44-7)
(8W-44-7)
* WITH GAS ENG
' - • ' ' * * WITH DIESEL ENG
8040d0bc J968W-9
8W-44 INTERIOR LIGHTING 8W - 44 - 7
POWER
POSITIVE CENTER
TERMINAL
<8W-20-3 4) P
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH DIESEL
ENG)
tf-20-4)
CENTER CENTER
HIGH HIGH
MOUNTED COUNTED
STOP STOP
LAMP LAMP
NO. 1 NO. 2
(8W-51-9) C8W-51-9) * WITH GAS ENG
** WITH DIESEL E
8040d0be J968W
8W - 44 - 8 8W-44 INTERIOR LIGHTING BR
POWER
BATTERY FUSE 1 C180 DISTRIBUTION
POSITIVE CENTER
TERMINAL I
50A (1) A7
(8W-20-3,4)
10RD
BK
S147
8W-70-21
RIGHT
BATTERY
POSITIVE
TERMINAL *
(WITH DIESEL SPLICE ENGINE
ENG) S148 STARTER
C8W-20-4) (8W-70-21) MOTOR
(8W-21-3.4)
BLACK
* WITH GAS ENG

** WITH DIESEL ENG
40d0c0 J968W-9
BR 8W-44 INTERIOR LIGHTING 8W - 44 - 9
POWER
POSITIVE CENTER
TERMINAL
(8W-20-3.4)
RIGHT IGNITION
BATTERY SWITCH
POSITIVE
TERMINAL » ACC m
(WITH D I E S E L SPLICE ENGINE OFF !

C133 C212 |
ENG) S148 STARTER
(8W-20-4) (8W-70-21) MOTOR • A2 1 2 P K / B K -— «H 0"
<8W-21-3„4) (4) 1
FUSE START 'RUN j

S201 BLOCK (5): C212
C241 F U SE 15 C241 8W-70-26
-<f A22 12BK/0R-—( •A22 12BK/0R-
(27) 10A (23)

L10
22BR
LG
(28)' ^ C209 BACK-UP

JOINT S117 LI 18VT/BK- LAMP
CONNECTOR SWITCH
8W-70-9 C126 (8W-51-6)
C
LI 18VT/BK-<f- LI 18VT/BK—•*
PARK/
NEUTRAL
LI Ll 18VT/BK- POSITION
18VT SWITCH
BK (8W-51-6)
C133 WITH
(30)^ £ C209
AUTO
TRANS
L10 LI
22BR 22VT
LG BK
C208 C208
L10 LI
22BR 22VT
LG BK
(1)
i- - -
r i
"
C334
DAY/NIGHT
""""^
FUSED BACK-UP
IGN SW LAMP
MIRROR
SWITCH (WITH
OUTPUT
OUTPUT HIGH-LINE
(RUN)
CLUSTER)
GND
S319
(2) C334
t •Z4 22BK-
8W-70-40
•Z4 18BK-
G304
8W-15-15
* WITH GAS ENG

8040d0c2 J968W-9
BR 8W - 46 MESSAGE CENTER 8W - 46 - 1
8W-46 M E S S A G E CENTER
DESCRIPTION AND OPERATION Circuit G86 is connected from the message center
to the PCM and is used for the WATER I N FUEL
MESSAGE CENTER lamp. The WATER-IN-FUEL lamp is only used on
Power for the message center is supplied on circuit vehicles equipped with the diesel engine. Circuit G86
F14. This circuit is HOT in the START and RUN connects to cavity C18 of the PCM.
position and protected by a 15 amp fuse located i n
cavity 12 of the fuse block. HELPFUL 1IF0R1AT10I
Power for the fuse is supplied on circuit A21 from • Check the 40 amp fuse located i n cavity 3 of the
the ignition switch. Power for the A21 circuit is sup PDC
plied on circuit A l . This circuit originates in the • Check the 15 amp fuse located i n cavity 12 of
Power Distribution Center (PDC) and is protected by the fuse block
a 40 amp fuse located in cavity 3. • Refer to the appropriate section of the service
The Powertrain Control Module (PCM) controls the manual or the diagnostic test procedures manual
ground path for the lamps in the message center.
Circuit G14 is connected from the message center
to the PCM and is used for the transmission warning
lamp. This circuit connects to cavity C7 of the PCM WIRING 01AGRA1 (N0E1
on all engine packages.
Circuit G85 is connected from the message center
to the PCM and is used for the WAIT-TO-START
lamp. The WAIT-TO-START lamp is only used with
8W-02 for a complete list of all components shown i n
the diesel engines. Circuit G85 connects to cavity
B20 of the PCM.
SW - 46 - 2 — 8W-46 MESSAGE CENTER ^ ^ BR
DIAGRAM INDEX
Fuse 3 ( P D C ) . . . . . . . . 8W-46-3 Message C e n t e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-46-3
Fuse 12 8W-46-3 Powertrain Control M o d u l e . . . . . . . . . . . . . . . . . . . . . 8W-46-3
Ignition Switch 8W-46-3
8040d0c3 J968W-9
BR 8W-46 MESSAGE CENTER 8W - 46 - 3
SPLICE
•AO 20BK* AO 1 4 P K * * •
BATTERY S148
POSITIVE ENGINE (8W-70-21)
TERMINAL STARTER
(8W-20-3,4) MOTOR
(8W-21-3,4)
POWERTRAIN
CONTROL
RIGHT MODULE C133
BATTERY
Al 12RD -)>—Al 12RD
POSITIVE
TERMINAL
(WITH DIESEL
ENG)
(8W-20-4)
•F14 18LG/YL A21 12DB
S209
8W-70-30
F14
20LG MESSAGE
YL WATER WAIT
CENTER
FUSED -IN-
C224 -TO- TRANS
IGNITION FUEL START TEMP
SWITCH WARNING WARNING SRI LAMP
OUTPUT LAMP
(3) LAMP LAMP DRIVER
(START/ DRIVER DRIVER DRIVER (AUTO
RUN) (DIESEL) (DIESEL) (GAS) TRANS)
(4) C224 (8)~J^ C224

-
G86 G85 G24

—T ~ G14
20TN 200R 22GY
20PK
OR BK PK
BK
C133 C133
G86 G85 G24 G14

18TN 180R 20GY 18PK
OR BK PK BK
C125 C126 C125
G86 G85 G24 G14

18TN 180R 20GY 18PK
OR BK PK BK
!
^
C18
C137 ^ C136
B20
k C18 C7
C137
! POWERTRAIN
CONTROL
i WATER WAIT SRI TRANS •
! -IN- -TO- LAMP TEMP ! MODULE
i FUEL START DRIVER LAMP i
J WARNING WARNING (GAS) DRIVER !
i LAMP LAMP (AUTO i
j DRIVER DRIVER TRANS) !
» (DIESEL) (DIESEL)
* WITH GAS ENG

** WITH DIESEL ENG
8040d0c5 J968W-9
BR 8W - 47 AUDIO SYSTEM 8W - 47 -1
8W-47 AUDIO SYSTEM
INDEX
page page
GENERAL INFORMATION RADIO MEMORY 1

INTRODUCTION 1 RADIO OPERATION 1
DESCRIPTION AND OPERATION SPEAKERS—PREMIUM RADIO 1
HELPFUL INFORMATION 2 SPEAKERS—STANDARD RADIO 1
RADIO CHOKE—PREMIUM RADIO ONLY 1 SCHEMATICS AND DIAGRAMS
RADIO ILLUMINATION 1 WIRING DIAGRAM INDEX 2
GENERAL INFORMATION RADIO CHOKE—PREMIUM RADIO ONLY

The radio choke relay supplies voltage to the
INTRODUCTION amplifier circuits in the speakers. The radio supplies
Two radio systems are available in this vehicle; one power to the coil side of the relay on circuit X60. Cir
with a standard speaker system and a radio with cuit Z2 provides ground for the coil side of the relay.
premium speaker system. The premium speaker sys The radio energizes the radio choke relay by pow
tem uses power amplifiers on the speakers, and a ering circuit X60. When the relay energizes, its con
radio choke relay not used on the standard system. tacts close and connect circuit M l from the Ignition-
When referencing the circuit descriptions or the dia Off-Draw (IOD) fuse in cavity 17 of the fuse block to
grams, ensure that you use the correct ones. circuit X13. Circuit X13 supplies voltage to the
amplifier circuits in the speakers.
DESCRIPTION AND OPERATION SPEAKERS—STANDARD RADIO
Circuit X53 feeds the speaker in the left front door.
RADIO OPERATION Circuit X55 is the return from the speaker to the
In the ACCESSORY or RUN position, the ignition radio.
switch connects circuit A l from fuse 3, a 40 amp, in Circuit X54 feeds the right front door speaker. Cir
the Power Distribution Center (PDC) with circuit cuit X56 is the return from the speaker to the radio.
A31. Circuit A31 powers a bus bar in the fuse block Circuit X51 feeds the speaker in the left rear of the
that feeds circuit X12 through fuse 7, a 10 amp. Cir vehicle. Circuit X57 is the return from the speaker to
cuit X12 supplies battery voltage to the radio. Circuit the radio.
Z2 provides ground for the radio. • Circuit X52 feeds the right rear - speaker. Circuit
X58 is the return from the speaker to the radio.
RADIO MEMORY
Circuit M l from the Ignition Off Draw (IOD) fuse SPEAKERS—PREMIUM RADIO
(Fuse 17) in the fuse block supplies power for the When the radio choke energizes, circuit X13 sup
radio memory. The IOD fuse is removed during vehi plies voltage to the amplifier circuits in each speaker.
cle shipping to prevent excessive battery draw. Circuit Z2 provides the ground path for the speaker
Circuit A7 from fuse 1, a 50 amp, in the Power Dis amplifiers.
tribution Center (PDC) supplies voltage to the IOD Circuit X53 feeds the speakers in the left front
fuse. Circuit A7 is HOT at all times. door. Circuit X55 is the return from the speakers to
the radio.
RADIO ILLUMINATION Circuit X54 feeds the right front door speakers.
When the parking lamps or headlamps are ON, cir Circuit X56 is the return from the speakers to the
cuits E2 and L7 from the headlamp switch power the radio.
radio illumination lamps. Fuse 13, a 5 amp, in the Circuit X51 feeds the left rear speaker. Circuit X57
fuse block powers circuit E2 which feeds the radio is the return from the speaker to the radio.
illumination lamp. Circuit E l from the headlamp Circuit X52 feeds the right rear speaker. Circuit
switch supplies power to fuse 13. Circuit L7 supplies X58 is the return from the speaker to the radio.
voltage for the radio lamps. Circuit Z2 supplies the
ground path for the illumination and park lamp cir
cuits.
8W - 47 - 2 8W - 47 AUDIO SYSTEM BR
HELPFUL INFORMATION you; are looking for is not found here, refer to section
• Check the 40 amp fuse located in cavity 3 of the 8W-02 for a complete list of all components shown i n
PDC the wiring diagrams.
fuse block
• Check the ground at the rear of the radio
• Check the IOD fuse in the fuse block

BR 8W-47 AUDIO SYSTEM
DIAGRAM INDEX
Component Pa
°e Component Page
Fuse 1 (PDC) 8W-47-4,6 Left Door Speaker 8W-47-5
Fuse 3 (PDC) 8W-47-4, 6 Left Door Tweeter 8W-47-8
Fuse 7 8W-47-4, 6 Left Rear Premium Speaker 8W-47-7
Fuse 13 8W-47-4.6 Left Rear Speaker 8W-47-5
Fuse 17 8W-47-4.6 Radio 8W-47-4 thru 9
Fuse 18 8W-47-4.6 Radio Choke 8W-47-7
Headlamp Switch 8W-47-4,6 Right Door Premium Speaker 8W-47-9
Ignition Switch 8W-47-4, 6 Right Door Speaker 8W-47-5
Joint Connector A 8W-47-4, 6 Right Door Tweeter 8W-47-9
Joint Connector B 8W-47-4,6, 7 Right Rear Premium Speaker 8W-47-7
Joint Connector C 8W-47- 4, 6 Right Rear Speaker 8W-47-5
Left Door Premium Speaker 8W-47-8
J968W-9
8040d0c7
8W - 47 - 4 8W-47 AUDIO SYSTEf
STANDARD RADIO
FUSE POWER
i ciao A 7
POSITIVE
TERMINAL
AO 6RD-
-c© annir- p ^ ^ > > — - IORD
50A B K
CENTER
(8W-20-3,4) S147
FUSE 8W-70-21
3
A7
40A (3) Al •12RD
RIGHT 12RD BK
BATTERY
POSITIVE ,
C133 C133
TERMINAL
(WITH DIESEL
SPLICE ENGINE
ENG)
S148 STARTER Al
(8W-20-4) C8W-70-21) S124 12RD A7
MOTOR
(811-21-3,4) 8W-70-12 12RD
BK
Al 12RD-
• A7 12RD/BK-
WITH
S204 POWER
SEAT
8W-70-28
•A7 1 2 R D / B K — © — A7 12RD/BK
OVERDRIVE
F©i L4MP SWITCH I L L i i H A T l i l
SWITCH LAMP J O I N T CONNECTOR C
C8W-50-10) (8W-31-7)
E2 220R
A7
12RD
BK WITH
FOG LAMPS
( 3 9 ) >{<
(43)
! FUSE FUSED PARK FUSED PANEL

i IGNITION B(+) LAMP LAMPS DIMMER
] SWITCH OUTPUT SWITCH SWITCH
i (ACC/RUN) OUTPUT SIGNAL
RADIO * WITH GAS ENG

** WITH DIESEL ENG
8040d0c9 J968W-9
BR 8W-47 AUDIO SYSTEM 8W - 4 7 - 5
STANDARD RADIO
LEFT DOOR RIGHT DOOR

SPEAKER SPEAKER
C312
X53 X55 X54 X56

20DG 20BR 20VT 20DB
RD RD
X53
T
X55
20BR
V X55
20BR
X54
20VT
X56
i r
X56
20DG 20DB 20DB
RD RD RD RD
t
X53 C347 X54 C345
20DG
C347 20VT
C345
X56
X53 X54 18DB
X55
18DG 18VT RD
18BR
OPTIONAL
RD
OPTIONAL
C201 C201 C240 V C24Q

X55 r X56
X53 20BR X54 20DB
20DG RD 20VT RD
( 4 ) ^ C230 ( 2 ) ^ C229 ( 5 ) ^ C230 ( 3 ) ^ C229
LEFT FRONT LEFT FRONT RIGHT FRONT RIGHT FRONT RADIO
DOOR SPEAKER DOOR SPEAKER DOOR SPEAKER DOOR SPEAKER
(+) (-) (+) (-)
LEFT REAR LEFT REAR RIGHT REAR RIGHT REAR

SPEAKER SPEAKER SPEAKER SPEAKER
(-) (+) (-) (+)
(6)
V—- J i i l j g €230 (3): C230
X57 X51 X58 X52

20BR 20BR 20DB 20DB
LB YL OR WT
C202 C202 C202 C202
X57 X51 X58 X52

18BR 18BR 18DB 18DB
LB YL OR WT
(A) : (B) C306 (B) : C302
RIGHT
^ ^ ^ - ^ REAR REAR
SPEAKER SPEAKER
8040dOcb J968W-9
8W - 47 - 6 - 8W-47 AUDIO SYSTEM — BR
PREMIUM STEREO RADIO
„ „ „
POWER
BATTERY i ciso A7 DISTRIBUTION
POSITIVE AO 6RD- •10RD CENTER
TERMINAL 50A ( 1 ) BK
C8W-20-3,4) $147
AO AO FUSE 8W-70-21
AO
OERD 20BK* 6RD* 3
RIGHT 1
BATTERY I ENGINE A7
t
AO A 0 STARTER 40A ( 3 ) Al •12RD
POSITIVE „J 14PK** GOERD**" *~ MOTOR 12RD BK
TERMINAL
(8W-21-3,4>
(WITH DIESEL C133 C133
ENG) SPLICE
• $148 $124
(8W-20-4) A7
C8W-70-21) 8W-70-12 Al
12RD 12RD
Al 12RD — — — BK
• A7 12RD/BK-
WITH
S204 POWER
8W-70-28 SEAT
* s — A7 12RD/BK •A7 12RD/BK-
OVERDRIVE SWITCH
FOG LAMP ILLUMINATION
SWITCH LAMP JOINT CONNECTOR C
(SW-50-10) C8W-31-7)
FUSE FUSED PARK FUSED PANEL

IGNITION B(+) LAMP LAMPS DIMMER
SWITCH OUTPUT SWITCH SWITCH
(ACC/RUN) OUTPUT SIGNAL
RADIO * WITH GAS ENG
** WITH DIESEL ENG
8040d0cc J968W-9
BR - 8W-47 AUDIO SYSTEM - 8W - 47 - 7
LEFT mm RIGHT REAR

S302 PREMIUM PREMIUM
SPEAKER SPEAKER
8W-70-34 X13
18BK
RD
X13 X13
18BK 18BK
RD RD
(4): ^^T^îll^ C305 (4): C301

C202
X51 X57
X52 X58 S301
18BR 18BR
18DB 18DB
WT OR •Z2 18BK/LG-
YL LB
X13 C2Q2^ C202
18BK
RD
T T X52
X51 X57 20DB
S2I3 20BR 20BR WT
8W-70-32 YL LB
A-
LEFT REAR LEFT REAR
SPEAKER ( + ) SPEAKER ( - )
FUSED RADIO 12 VOLT
B(+) OUTPUT
X13 "J
18BK
RD Ml
20PK"
C231
SPLICE
S205
C8W-47-6)
(8W-70-28)
8040d0ce J968W-9
8W-47-8- - 8W-47 AUDIO SYSTEM - BR
LEFT POOR
PREMIUM
SPEAKER
Z2 18BK/LG-
|
Z2
18BK
LG
C347 Z2
OPTIONAL 18BK
LG
Z2
18BK
LG
X13 Z2
18BK 18BK
RD LG
1
C201
+
X13 C201
18BK C201
RD
X53 1 8 D G — |
•1
! $213
8W-70-32 X53
20DG
ZQ
R f Z2
18BK
LG
X13
18BK (4)^ C230 (2) ^ C229
RADIO
RD LEFT FRONT LEFT FRONT
DOOR SPEAKER DOOR SPEAKER
(.+) (-)
S212
RADIO 8W-70-31
Z2
CHOICE WITH 18BK-
(8M-47-7) ABS LG
-Z2 18BK/LG- Z2 Z2
18BK 18BK
0107 LG LG
8W-15-9
^T' ^ C133
Z2 Z2
18BK 18BK
WITH LG LG
RWAL
-Z2 18BK/LG-
G103
$122
8W-15-5 8W-70-11
8040d0d0 J968W-9
- 8W-47 AUDIO SYSTEM - 8W - 47 - 9
RIGHT DOOR
PREMIUM
SPEAKER
RADIO
CHOKE
(8W-47-7)
T
Z2
T-CI33
Z2
18BK 18BK
LG LG
*> I
8W-70-11
8040d0d2 J968W-9
BR 8W - 41 OVERHEAD CONSOLE iW -41-1
8W-49 O V E R H E A D C O N S O L E
DESCRIPTION AND OPERATION door jamb switches. The door jamb switches connect
to ground on circuit Z3. When a door is OPENED,
OVERHEAD CONSOLE the plunger in the switch CLOSES, completing a
When the ignition switch is i n the RUN or START path to ground.
position, circuit F12 from fuse 11, a 10 amp, in the The second ground path is through the headlamp
fuse block supplies power to the overhead console. switch. When the operator turns the headlamp
When the headlamps or parking lamps are ON, cir switch to the dome lamp ON position, a ground path
cuits L7 and E2 provide voltage to the overhead con provided on circuit M2 through the switch to ground
sole. Circuit E2 from fuse 13, a 5 amp, in the fuse on circuit Z3.
block powers the illumination lamps in the overhead
console. Circuit E l from the headlamp switch feeds HELPFUL INFORMATION
fuse 13 and circuit E2. • Check the 15 amp fuse located in cavity 17 of
Circuit Z l l provides ground for the compass. the fuse block
• Circuit M l splices to supply voltage for the radio
AMBIENT TEMPERATURE SENSOR memory, time delay relay, underhood lamp, and glove
The ambient temperature sensor is a variable box lamp.
resistor. Circuit G31 supplies voltage from the over • Circuit E2 splices to provide voltage to the
head console to the sensor. Circuit G32 is the signal instrument cluster illumination lamps, and radio
return from the sensor to the overhead console. lamp.
• Check the 10 amp fuse i n cavity 11 of the fuse
LAMPS block
Circuit M l supplies voltage for the reading lamps, • Check the grounding point for the overhead con
map lamp, and dome lamp in the overhead console. sole
The Ignition Off Draw (IOD) fuse (fuse 17) in the
fuse block supplies voltage to circuit M l . Circuit A7
from fuse 1 in Power Distribution Center (PDC) feeds
the IOD fuse.
Circuit Z4 grounds the reading lamps and map
lamps. Circuit M2 provides ground for the dome The following index covers all components found i n
lamp. this section of the wiring diagrams. I f the component
The M2 circuit supplies ground for the overhead you are looking for is not found here, refer to section
console dome lamp in two ways. One way is through 8W-02 for a complete list of all components shown i n
the door jamb switches. Circuit M2 connects to the the wiring diagrams.
8W - 49 - 2 8W-49 OVERH :AD CONSOLE — — — — BR
DIAGRAM INDEX
Ambient Temperature Sensor 8W-49-5 Ignition Switch 8W-49-3
Fuse 1 (PDC) 8W-49-3 Joint Connector A 8W-49-3.4, 5
Fuse 3 (PDC) 8W-49-3 Joint Connector C 8W-49-3, 4
Fuse 11 8W-49-3 Lett Door Jamb Switch 8W-49-4
Fuse 13 8W-49-3 Overhead Console 8W-49-3, 4, 5
Fuse 17 8W-49-3 Overhead Map/Courtesy Lamp 8W-49-5
Fuse 18 8W-49-3 Right Door Jamb Switch 8W-49-4
Headlamp Switch 8W-49-3, 4
8040d0d4 J968W-9
BR 8W-49 OVERHEAD CONSOLE 8W-4I-3
POWER
FUSE 1 Mil
POSITIVE CENTER
TERMINAL 50A (1)1 A7
<8W-20-3,4) 10RD
BK S147
8W-70-21
I
RIGHT 40A (3) A7
BATTERY _j Al
AO AO 12RD
1-2 RD
POSITIVE 14PK** OOERD** BK
TERMINAL
(WITH DIESEL
ENG)
SPLICE ENGINE ' C133
(8W-20-4) S148 STARTER
(8W-70-21) MOTOR
(8W-21-3.4)
S124
I8W-70-12I C133 A7
r •Al 12RD- •Al 12RD (f- 12RD

BK
j
^ A7 12RD/BK
IGNITION S204
SWITCH 18W-70-28]
START
V
t \ * !
- * ~ A 7
• OVERDRIVE
12RD/BK — # — A 7 12RD/BK-
V , i^-V
RUN OFF
ACC;
,
SWITCH ILLUMINATION WITH
LAMP WITH POWER SEAT
A7 (M-31-7) FOG LAMPS
12RD
FOG LAMP
(2) ^£ C212 BK
E2 220R- • SWITCH
JOINT C8W-50-10)
CONNECTOR C
A21
C209 C209
12DB
E2 200R-
<5) j(4)
220 R
(31) (25)
FUSE FUSE
11 18 C208
10A K
15A S
15A
(35): (17): (18): (21) E2

220R
F33
Ml
18PK
20PK <f
RD (12) (15)
S205
F12
8W-70-28 M M 22DB
r Ml 20PK-I F12 £898 WT
(B2) (I) C206 1
r-22DB—))
HEADLAMP WT
C208 SWITCH
F12 HEAD I JOINT (7): Til ^ C338
Ml
22DB --r - AAAr CONNECTOR A FUSED j
20PK 0 F F i FUSED
WT PARK
! IGN SWITCH PANEL LAMPS
SPLICE PARK
(R) C206 i OUTPUT DIMMER |
S320 C217 LAMP
! (START/ SWITCH i
(8W-49-4) SWITCH
i RUN) SIGNAL ]
(8W-70-41I
L7 20BK/YL- -<f OUTPUT
(10)*- OVERHEAD CONSOLE
(WITH H I G H - L I N E C L U S T E R )
* WITH GAS ENG
* * WITH D I E S E L ENG
8040d0d6 J968W-9
8W - 49 « 4 8W-49 OVERHEAD CONSOLE BR
S320
SPLICE C208 8W-70-41 OVERHEAD
S205 -Ml 20PK- -Ml 20PK- -Ml 20PK-
NAP/COURTESY
(8W-49-3) LAMP
(8W-70-28) (8W-49-5)
Ml 18PK-
WITH
-Ml 18PK- LOW-LINE
CLUSTER
OVERHEAD
OVERHEAD NAP/COURTESY
CONSOLE •M2 2 2 Y L - LAMP
(WITH H I G H - L I N E (8W-49-5)
CLUSTER)
C338
-)> M2 2 2 Y L - M2
22YL
(6)
C208
M2
22YL
JOINT CONNECTOR A
C217
~<f
(7)
(1) : (8): (2) C217
M2 2 0 Y L - M2 M2
22YL 22YL
C201
M2 18YL »
C240
M2
18YL
(2) C319
RIGHT
DOOR
JAMB
LEFT
SWITCH
FRONT OPTIONAL
DOOR (1) ' C319
Z3 Z3
JAMB
20BK 18BK
SWITCH
Z3 OR OR Z3
SENSE
12BK 18BK
OR OR
G201 G302 G303

I8W-15-13) I I [8 W - 1 5 - 1 4 I # |8W-15-15|
8040d0d8 J968W-9
BR 8W-49 OVERHEAD CONSOLE 8W - 4 9 - 5
OVERHEAD
JOINT CONSOLE
CONNECTOR C208 (8W-49-4)
A. -M2 22YL — M2 22YL
(8W-49-4)
(8W-12-4) SPLICE
S320 WITH
C8W-49-4) LOW-LINE
(8W-70-41) CLUSTER
G304
8W-15-15
•14 18BK
SENSOR
HEADLAMP C217 JOINT

L7 20BK/YL <f- CONNECTOR (1) (2) : €114
SWITCH A
(8W-49-2) (10)
G31 G32
i
18VT 18BK
(5) C217 LG VTX
L7
20BK
YL C133
C208
S208 G31 G32

• Z l l 18BK/WT- 8W-70-30 WITH 22VT 22BK
CLEARANCE LG VT
AND I.D.
L7 L7 LAMPS
Zll 20BK 18BK
20BK YL YL
WT
S317 C208
8W-70-40
C208
L7
18BK
G202 YL G31 G32
• 8W-15-13 Zll 22VT 22BK
20BK LG LB
WT
(90^ (2) <T- (5) (4) C338

_, _ _, . i .„„ OVERHEAD
GROUND PARK LAMP CONSOLE
SWITCH (WITH
OUTPUT HIGH-LINE
CLUSTER)
8040dOda J968W-9
BR SW - 50 FRONT LIGHTING 8W -50-1
8W-50 F R O N T LIGHTING
INDEX
page page
DESCRIPTION AND OPERATION PARKING LAMPS . 1

DAYTIME RUNNING LAMP (DRL) MODULE 1 SCHEMATICS AND DIAGRAMS
FOG LAMPS 1 WIRING DIAGRAM INDEX 2
HEADLAMPS 1
DESCRIPTION AND OPERATION HEADLAMP GROUND

Although circuit Z l provides ground for both the
PARKING LAMPS right and left headlamps, it has different termination
The headlamp switch has three positions: OFF, points for each.
PARK (parking lamps) and ON, plus a dimmer
switch. When the headlamp switch is in the PARK or FOG LAMPS
ON position, the switch connects circuit F33 to cir The fog lamps are controlled by the fog lamp
cuit L7. From the headlamp switch, circuit L7 switch and fog lamp relays. The fog lamps operate
branches to power the front parking lamps and rear only when the headlamp switch is in the PARK or
tail lamps, roof identification lamps, fender lamps ON position, and the operator has selected low-beam
and rear license plate lamps. Circuit Z l provides a operation. When the headlamps are in high-beam
ground for the parking lamps. Ground for the roof operation, the fog lamps will not operate.
clearance and identification lamps is supplied on cir Power for fog lamp relay #1 is supplied on circuit
cuit Z4. L7. This circuit is HOT when the headlamp switch is
in the PARK or ON position only and connects to the
HEADLAMPS normally CLOSED contacts of the relay.
The headlamp switch has three positions: OFF, Circuit L139 connects from the contact side of the
PARK (parking lamps) and ON. The headlamp switch relay #1 to the coil side of relay #2. When the oper
powers the headlamps through the multi-function ator turns the fog lamps ON a ground path is com
switch. pleted on circuit L35 through the fog lamp switch to
circuit Z3. This causes the contacts in relay #2 to
FLASH-TO-PASS (OPTICAL HORN) CLOSE connecting circuits L38 and L39.
Circuit A3 from fuse 6, a 40 amp, in the Power Dis Circuit L38 is the feed for the relay and protected
tribution Center (PDC) supplies battery voltage to by a 15 amp fuse located in cavity A of the Power
the headlamp switch. The headlamp switch has an Distribution Center (PDC). Circuit L39 connects from
internal circuit breaker that connects circuit A3 to the relay to the lamps. Ground for the lamps is sup
circuit L20. plied on circuit Z l
In the OFF or PARK position, the headlamp switch If the high beam lamps are on, circuit G34 ener
feeds circuit L20 which connects to the multi-func gizes the fog lamp #1 relay. When the relay ener
tion switch. Circuit L20 powers the high-beam on cir gizes, the contacts OPEN and power is not .supplied
cuit L3 when the operator flashes the headlamps to the fog lamps. Circuit Z l provides ground for the
with the turn signal stalk of the multi-function coil side of the fog lamp #1 relay.
switch.
DAYTIME RUNNING LAMP (DRL) MODULE
HEADLAMP SWITCH IN ON POSITION On vehicles built for sale in Canada, the low-beam
When the headlamp switch is in the O N position, headlamps operate when the ignition switch is in the
circuit A3 connects to circuit L2. Circuit L2 connects RUN position and the park brake switch is OPEN.
to the multi-function switch and feeds the low beams Circuit L10 from fuse 15 in the fuse block supplies
on circuit L4. voltage to the DRL module. Circuit A3 from the PDC
When the operator selects high beam operation, connects to DRL module.
circuit L2 connects to circuit L3. The DRL module receives information on park
brake switch position on circuit G i l .
Circuit L4 powers the low beams of the headlamps.
When the headlamp switch is OFF, the DRL module
8W - 50 - 2 8W - 50 FRONT LIGHTING BR
powers the low beams on circuit L4. When the head SCHEMATICS AND DIAGRAMS
lamps are ON, the multi-function switch powers the
low beams on circuit L4. WIRING DIAGRAM INDEX
Circuit L3 feeds the high beams of the headlamps. The following index covers all components found in
When the operator flashes the headlamps with the this section of the wiring diagrams. I f the component
stalk of the multi-function switch, the DRL senses you are looking for is not found here, refer to section
voltage on circuit L3 and stops supplying power to 8W-02 for a complete list of all components shown in
the low beams on circuit L4. Circuit Z l provides the wiring diagrams.
ground for the DRL module.
BR 8W-50 FRONT LIGHTING 8W - 50 - 3
DIAGRAM INDEX
Component Pap Component Page
Center Identification Lamp 8W-50-6 Ground Joint 8W-50-5
Controller Anti-Lock Brake 8W-50-11 Headlamp Dimmer Switch 8W-50-4
Daytime Running Lamp Module 8W-50-4,12 Headlamp Switch 8W-50-4, 8
Fog Lamp Relay No. 1 8W-50-8 Headlamps 8W-50-5
Fog Lamp Relay No. 2 8W-50-9 Ignition Switch 8W-50-11
Fog Lamp Switch 8W-50-10 Instrument Cluster 8W-50-4, 5,11
Fog Lamps 8W-50-10 Joint Connector A 8W-50-5, 6, 8
Fuse 1 (PDC) 8W-50-7, 9 Joint Connector C 8W-50-8,11
Fuse 2 (PDC) 8W-50-11 Outboard Clearance Lamps 8W-50-6
Fuse 6 (PDC) 8W-50-4,12 Outboard Identification Lamps 8W-50-6
Fuse 13 8W-50-8 Overhead Console .. 8W-50-6
Fuse 15 8W-50-11 Park Brake Switch 8W-50-11
Fuse 18 8W-50-7 Park/Turn Signal Lamps 8W-50-5
Fuse A 8W-50-9 Turn Signal/Hazard Switch 8W-50-5
J968W-9
8040d0dc
8W - 50 - 4 8W-50 FRONT LIGHTING mm
SPLICE
-AO 20BK* AO 14PK**- S148
BATTERY (8W-70-21)
POSITIVE
TERNINAL
(8W-20-3,4)
RIGHT
BATTERY
POSITIVE
TERNINAL
(WITH
DIESEL ENG)
C8W-20-4)
RIGHT
HEADLAMP * WITH GAS ENG
(8W-50-5) ** WITH DIESEL ENG
8040d0de J968W-9
BR- ^ 8W-50 FRONT LIGHTING 8W - 50 - 5
RIGHT P A R K / T U R N INSTRUMENT LEFT PARK/TURN

SPLICE HEADLAMP
S I G N A L LAMP CLUSTER S I G N A L LAMP
RIGHT LEFT S121 DIMMER
C101 C1Q1 TURN TURN C112 C112 (8W-50-4) SWITCH
SIGNAL SIGNAL (8W-70-10) (8W-50-4)
a) (3)
(14): C216
^ 3 )
(2) C1Q1 L61 ( 2 ) : C112 L3 L4
L60 18LG 16RD 16VT
18LG TN RIGHT OR WT
TN HEADLAMP
S102 C133^
C102
8W-70-3 L4
16VT
L7 L60 ^ ^ l L 4 16VT/WT-, WT
18BK 20TN
I
YL BK
(Ar S107
C133
8W-70-4
L—)>—18TN- 17
Zl
BK 18BK
18BK
(11): C210 YL Zl
TURN 18BK L4
SIGNAL/ 16VT
LT HAZARD WT
TURN
SWITCH Zl
C210 20BK
it
DAYTIME
(15) RUNNING
C210
NORMAL ^ LAMP
—» LEFT MODULE
(17)| CAVITY 10
< f HEADLAMP
(8W-50-12)
(12) C113
HAZARD
))-L3 16RD/0R-
(C)
^RT#- ))1-L4 16VT/WT-
TURN
Zl 20BK-
7 A
(A)
(13)
SPLICE
S121
(8W-50-4)
S101 (14) C210 S106 (8W-70-10)
8W-70-3 8W-70-4
L7 2 0 B K / Y L — I
C133
/
L7 1 8 B K / Y L — > L7 20BK/YL—| G105
L7
r«- (3) C123 © 8W-15-6.7.8
18BK L7 20BK/YL—
Q^P*"] iROUND
YL FOG LAMP [ ! JOINT
R E L A Y NO. 1
C217 (8W-50-8)
(4): (10):
(8W-11-13.14) Zl
JOINT
18BK
CONNECTOR
A
HEADLAMP
SWITCH
(8W-50-8)
S103
8W-70-3 G102
Zl 18BK- 8W-15-4
8040d0e0 J968W-9
8W - 50 - 6 8W-5Q FRONT LIGHTING
JOINT
CONNECTOR
PARK
A
LAMP L E F T OUTBOARD
SWITCH C L E A R A N C E LAMP
OUTPUT
( 5 ) ^ C217
L7 18BK/YL Z4 18BK-
L7
20BK
YL
C208 L E F T OUTBOARD
I D E N T I F I C A T I O N LAMP
C336
L7 18BK/YL Z4 18BK-
WITH
CLEARANCE
AND
L7
I.D.
18BK
LAMPS
YL
CENTER
L7 IDENTIFICATION
20BK S317
YL
LAMP S318
8W-70-40
C339 C339 I8W-70-40
L7 18BK/YL- Z4 18BK-
(1) (2)
L7
18BK
YL
Z4
RIGHT OUTBOARD 18BK
I D E N T I F I C A T I O N LAMP
C340 C340
L7 18BK/YL- •Z4 18BK-
(1) (2)
(2) C338
WITH
OVERHEAD RIGHT OUTBOARD CLEARANCE
PARK
CONSOLE C L E A R A N C E LAMP AND
LAMP
SWITCH (WITH I.D.
OUTPUT HIGH-LINE C341 C341 LAMPS
CLUSTER) L7 18BK/YL- Z4 18BK-
(1) (2)
G304
8W-15-15
8040d0e2 J968W-9
BR 8W-50 FRONT LIGHTING 8W - 50 - 7
SPLICE
AO 2 0 B K * - AO 1 4 P K * * - S148
BATTERY (8W-70-21)
ENGINE
POSITIVE ^ STARTER
TERMINAL AO 6RD* -AO OOERD*
MOTOR
(8W-20-3.4) (8W-21-3,4)
AO AO
OERD 6RD
POWER
RIGHT
DISTRIBUTION
BATTERY
CENTER
POSITIVE FUSE 1 C180
TERMINAL
» - k l 10RD/BK—I
(WITH
DIESEL ENG)
(8W-20-4)
50A (1) I $147
8W-70-21
A7
12RD
BK
C133
•A7 12RD/BK-
• A7 12RD-
-A7 12RD/BK- •A7 12RD/BK-

A7 S204
12RD
BK 8W-70-28
WITH
POWER
SEAT
FUSE
; d 4 ) '^ C 2 4 1 ! BLOCK
c) FUSE !
I 18 i
I <i 15A !
! ( 1 8 ) v£ C 2 4 i ;
F33
20PK
RD
HEADLAMP
SWITCH
(8W-50-8)
* WITH GAS ENG

** WITH DIESEL ENG
8040d0e4 J968W-9
8W - 50 - 8 8W-50 FRONT LIGHTING BR
FUSE LEFT P A R K / RIGHT P A R K /
BLOCK TURN S I G N A L TURN S I G N A L
(8W-50-7) LAMP LAMP
C8W-10-11) C8W-50-5) rf-50- 5 )
A
f
17
18BK
YL
•1 S101
8W-70-3
DAYTIME
RUNNING
LAMP
MODULE
CAVITY 4
C8W-50-12)
8040d0e6 J968W-9
BR 8W-50 FRONT LIGHTING 8W -10 - 9
SPLICE
AO 2 0 B K * - AO 14PK* S148
BATTERY (8W-70-21)
ENGINE
POSITIVE
AO OOERD** *
^ STARTER
TERNINAL
MOTOR
<8W-2©-3,4) (8W-2I-3.4)
AO 6RD•
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH
DIESEL ENG)
(8W-20-4)
POWER
FOG LAMP DISTRIBUTION
R E L A Y NO. 1 CENTER
(8W-50-8)
C180 FUSE A M M '
(8W-11-13.14)
(A2) 15A (Al)
50A
L139 L38
20LB 20LB
A7 (1) : C180
WT BK
12RD
BK A7
(86) : (87) C180 10RD
BK
FOG S147
LANP
8W-70-21
1
T TI
RELAY
NO. 2
(85) :
5 ( 3 0 ) Sci80
L35 L39
22BR 20LB
WT
S104
8W-70-3 C105
RIGHT
-L39 20LB- 4> •L39 20LB- • FOG L A N P
C133 (8W-50-10)
LEFT
L35 L39 2 0 L B - -L39 20LB- * FOG LAMP
22BR (8W-50-I0)
WT
FOG L A N P
SWITCH
(8W-50-10) * WITH GAS ENG
** WITH DIESEL ENG
8040d0e8 J968W-9
8W - 5 0 - 1 0 8W-50 FRONT LIGHTING BR
FOG LAMP
OVERDRIVE
SWITCH
ILLUMINATION
LAMP
(8W-31-7)
G201
# 8W-15-13
G202
• 8W-15-13
8040d0ea J968W-9
BR 8W-50 FRONT LIGHTING 8W-50-11
SPLICE
AO 20BK*- - AO 14PK**- S148
BATTERY (8W-70-21)
ENGINE
POSITIVE
AO 6RD*- ^ STARTER
TERMINAL -AO OOERD**-
MOTOR
(8W-20-3,4)
<8W-21-3,4)
POWER
DISTRIBUTION
RIGHT CENTER
FUSE 2 C18Q C212
BATTERY
(MI- -S\j-m » r-A2 12PK/BK—<f
POSITIVE
TERMINAL 40A (2) (4)
(WITH A2
DIESEL ENG) 12PK C133
(8W-20-4) BK
S146
A2
8W-70-20 -12PK— 1
BK -A22 12BK/0R
FUSE
S201
CONTROLLER BLOCK
ANTI-LOCK. 8W-70-26
BRAKE
R BLACK (RWAL)
INSTRUMENT
-A22 12BK/0R—
(23) C241
PARK CLUSTER
BRAKE FUSE
SWITCH <? 15
SENSE
PARK
Gil 4 10A
BRAKE
20WT , _J (27):
SWITCH BK (5) ^ £216 C241
L fJ Gil
22WT
L10
22BR
CASE BK LG
- GROUND
(8): (10): 128)"^ C209
JOINT
C209 CONNECTOR
I C
(29) (30): (11): C209
- G i l 22WT/BK-
L10 DAYTIME
22BR C208 C133
DAY/NIGHT RUNNING
LG L-LIO 22BR/LG- L10 22BR/LG- MIRROR - G i l 20WT/BK • LAMP
(8W-44-9) MODULE
WITH HIGH-LINE CLUSTER CAVITY 3
•L10 18BR/LG
C133
•L10 18BR/LG-
C126
-L10 18BR/LG-
"1 (8W-50-12)
f WITH
— MAN
S120 1
L10 L10 TRANS
8W-70-10 C126
18BR 18BR
L10 L10 L10 LG LG
-20BR' -18BR « 18BR 1
LG 1
LG LG -» T ?
PARK/ BACK-UP
WITH
DRL NEUTRAL LAMP
D A Y T I M E RUNNING POSITION SWITCH
LAMP MODULE SWITCH (8W-51-6)
1
— L 1 0 18BR/LG- CAVITY 5 (8W-51-6)
** WITH DIESEL ENG
8040d0ec J968W-9
8W-50-12- 8W-50 FRONT LIGHTING BR
WITH DAYTIME RUNNING LAMPS
SPLICE
-AO 20BK* AO 14PK** — S148
POSITIVE ^ STARTER
TERNINAL •AO 6RD*- -AO OOERD*
NOTOR
(8W-20-3.4) (8W-21-3.4)
• AO 6RD-
RIGHT .
BATTERY
POSITIVE
TERNINAL POWER
(WITH DISTRIBUTION
DIESEL ENG) CENTER
C8W-20-4)
7 FUSE
6
40A
(6) C180
$118
8W-70-9
1
C133 — A 3 12RD/LG• •A3 12RD/LG-
A3 C133 JOINT
12RD - G i l 22WT/BK- CONNECTOR C
LG (8W-50-11)
(8W-12-7)
A3 Gil
20WT SPLICE
12RD •LIO 18BR/LG- S120
SPLICE LG BK
(8W-50-I1)
S203
(8W-50-4)
(8W-70-27) i:6
FUSED
3
PARK
5
FUSED
C131
(8W-70-10)
DAYTINE
RUNNING
B( + ) BRAKE IGNITION LAMP
SWITCH SWITCH NODULE
SENSE OUTPUT
(RUN)
DIMMER HIGH DIMMER
SWITCH BEAM SWITCH
HIGH INDICTOR LOW
BEAM LAMP BEAM
OUTPUT GND GND DRIVER OUTPUT
1 9 4 10
k „ df _. <> >JI £ C131
z1 Z1
18 BK 18 BK
G34 L4
16RD 18RD 16VT
OR GY WT
SPLICE SPLICE SPLICE

S121 S153 S107
(8W-50-4) C8W-50-4) CSW-50-5) * WITH GAS ENG
(8W-70-10) C8W-70-23) C8W-70-4) ** WITH DIESEL ENG
8040d0ee J968W-9
an 8W • 51 REAR LIGHTING 8W - 51 -1
8W-51 REAR LIGHTING
INDEX
page page
DESCRIPTION AND OPERATION TAIL LAMPS AND REAR LICENSE PLATE

BACK-UP LAMPS 2 LAMPS . . . ' .............. 1
FENDER AND TAILGATE LAMPS 1 SCHEMATICS AND DIAGRAMS
STOP LAMPS AND CHMSL LAMPS . . . . . . . . . . . . 1 WIRING DIAGRAM INDEX . . . . . . . . . . . . . . . . . . 2
.DESCRIPTION A N D O P E R A T I O N in the PDC protects the A7 circuit. Fuse 18, a 15

amp, in the fuse block protects circuit F33.
TAIL LAMPS AND REAR LICENSE PLATE LAMPS The headlamp switch has three positions: OFF,
Circuit A7 in the Power Distribution Center (PDC) PARK (parking lamps) and ON, plus a dimmer
connects to a bus bar in the fuse block. One of the switch. When the headlamp switch is in the PARK or
four circuits powered by the bus bar is circuit F33. ON position, the switch connects circuit F33 to cir
Circuit F33 connects to the headlamp switch. Fuse 1 cuit L7. From the headlamp switch, circuit L7
in the PDC protects the A7 circuit. Fuse 18, - a 15 branches to power the front parking lamps and rear
amp, in the fuse block protects circuit F33. tail lamps, roof clearance and identification lamps,
The headlamp switch has three positions: OFF, fender lamps and rear license plate lamps.
PARK (parking lamps) and ON, plus -a dimmer
switch. When the headlamp switch is in the PARK or GROUND CIRCUIT
ON position, the switch connects circuit F33 to cir Circuit Z13 provides ground for the lamps.
cuit L7. From the headlamp switch, circuit L7
HELPFUL INFORMATION
branches to power the front parking lamps and rear
• If the vehicle is equipped with factory installed
tail lamps, roof clearance and identification lamps,
fog lamps, circuit L7 splices to feed the fog lamp #1
fender lamps and rear license plate lamps.
relay
GROUND CIRCUIT • If the vehicle is equipped with factory installed
Circuit Z13 provides ground for the lamps. trailer tow, circuit L7 splices to the trailer tow har
ness
HELPFUL INFORMATION • Check fuse 1, a 40 amp, in the PDC
• If the vehicle is equipped with factory installed • Check fuse 18, a 15 amp, in the fuse block
fog lamps, circuit L7 splices to feed the fog lamp #1 • Circuit L7 also feeds the radio, if equipped
relay • When the headlamp switch is in the PARK or
• If the vehicle is equipped with factory installed ON position, the dimmer circuit, F33, also connects
trailer tow, circuit L7 splices to the trailer tow har to circuit E l . Circuit E l feeds circuit E2, which pow
ness ers the ash receiver lamp, instrument cluster illumi
• Check fuse 1, a 40 amp, in the PDC nation lamps, under hood lamp, glove box lamp and
• Check fuse 18, a 15 amp, in the fuse block radio lamp. Fuse 13 in the fuse block protects cir
• Circuit L7 also feeds the radio, if equipped cuits E l and E2
• When the headlamp switch is in the PARK or
ON position, the dimmer circuit, F33, also connects STOP LAMPS AND CHMSL LAMPS
to circuit E l . Circuit E l feeds circuit E2, which pow Circuit A3 from fuse 6, a 40 amp, in the Power Dis
ers the ash receiver lamp, instrument cluster illumi tribution Center (PDC) supplies voltage to circuit
nation lamps, under hood lamp, glove box lamp and F32 through fuse 20, a 15 amp, in the fuse block.
radio lamp. Fuse 13 in the fuse block protects cir Circuit F32 connects to the stop lamp switch.
cuits E l and E2 When the operator presses the brake pedal, the
stop lamp switch CLOSES and connects circuit F32
FENDER AND TAILGATE LAMPS to circuit L50. Circuit L50 connects to the Center
Circuit A7 in the Power Distribution Center (PDC) High Mounted Stop Lamps (CHMSL) and multi-func
connects to a bus bar in the fuse block. One of the tion switch. The multi-function switch supplies power
four circuits powered by the bus bar is circuit F33. to the L62 and L63 circuits. Circuit L62 powers the
Circuit F33 connects to the headlamp switch. Fuse 1
8W - 51 - 2 8W • 51 REAR LIGHTING -BR
right stop lamp. Circuit L63 powers the left stop the back-up lamp switch is part of an assembly that
lamp. includes the PARK/NEUTRAL position switch.
When the operator puts the transmission i n
GROUND CIRCUIT REVERSE, the back-up lamp switch connects circuit
Circuit Z13 provides a ground for the stop lamps L10 to circuit L I . Circuit L I feeds the back-up lamps.
and back-up lamps. The Z13 circuit has more than
one branch. Circuit Z13 also supplies ground path for GROUND CIRCUIT
the tail lamps, parking lamps, rear license plate Circuit Z13 provides ground for the back-up lamps.
lamp, back-up lamps, and turn signals. Circuit Z3 Circuit Z13 also supplies a ground path for the tail
provides ground for the CHMSL lamps. lamps, parking lamps, rear license plate lamp, stop
lamps, and turn signals.
HELPFUL INFORMATION
• Check for blown fuse in circuit F32. HELPFUL INFORMATION
• Check for continuity across the stop lamp switch • Check for blown fuses in circuits A2 and L10
when it is CLOSED. • Check for continuity across the back-up lamp
• I f the vehicle is equipped with Rear Wheel Anti- switch when i t is CLOSED
Lock (RWAL) brakes, circuit F32 connects to the • Circuit L I also connects to the day/night mirror
RWAL module.
BACK-UP LAMPS SCHEMATICS AND DIAGRAMS

In the RUN position, the ignition switch connects
circuit A2 from fuse 2 in the Power Distribution Cen WIRING DIAGRAM INDEX
ter (PDC) to circuit A22. Circuit A22 feeds a bus bar The following index covers all components found in
in the fuse block that powers circuit L10 through this section of the wiring diagrams. I f the component
fuse 15. you are looking for is not found here, refer to section
Circuit L10 supplies power to the back-up lamp 8W-02 for a complete list of all components shown in
switch. On automatic transmission equipped vehicles, the wiring diagrams.
BR 8W-51 RE LIGHTING 8W - 51- 3
DIAGRAM INDEX
Back-Up Lamp Switch 8W-51-6 Headlamp Switch 8W-51-4,10,11
Back-Up Lamps 8W-51-7 Ignition Switch 8W-51-6
Center High Mounted Stop Lamps 8W-51-9 Joint Connector A 8W-51-4, 9,10,11
Forward Fender Lamps 8W-51-12 Joint Connector B 8W-51-8
Fusel (PDC) 8W-51-4,10,11 Joint Connector C 8W-51-6
Fuse 2 (PDC) 8W-51-6 License Lamps 8W-51-4.10
Fuse 6 (PDC) 8W-51-8 Stop Lamp Switch 8W-51-8
Fuse 15 8W-51-6 Park/Neutral Position Switch 8W-51-6
Fuse 17 8W-51-9 Rear Fender Lamps 8W-51-12
Fuse 18 8W-51-4.10.11 Stop Lamp Switch 8W-51-8
Fuse 20 8W-51-8 Tail, Stop and Turn Signal Lamps 8W-51-5
Tailgate Lamps 8W-51-11
8040d0f0 J968W-9
8W - 5 1 - 4 — — — • 8W-51 REAR LIGHTING — BR
BATTERY
SPLICE
POSITIVE AO 2 0 B K * - •AO 14PK**- S148
TERMINAL
(8W-70-21) WITH
(8W-20-3,4)
POWER
SEAT
S2Q4
8W-70-28
•A7 12RD/BK
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH
DIESEL ENG) A7 A7
(8W-20-4) 12RD 12RD
ENGINE BK BK
STARTER
MOTOR
<8W-21-3,4) ,1 i,
POWER
DISTRIBUTION A7
CENTER 12RD
SPLICE BK
$312
(8W-51-5)
(8W-70-38) C133
A7
Z13 12RD
18BK BK
C342
LEFT T A I L .
S T O P AND
RIGHT TURN S I G N A L
LICENSE LAiP
(8W-51-5)
L7 18BK/YL-
C342
C333 RIGHT T A I L ,
S T O P AND
LEFT (10) C217
TURN S I G N A L
LICENSE JOINT
LAMP
LAMP CONNECTOR
(8W-51-5)
A
SPLICE
S406
(8W-51-11)
: C343
WITH (8W-70-42)
DUAL
Z13 REAR "
18BK WHEELS
L7
18BK
YL
SPLICE
S312
(8W-51-5)
(8W-70-38)
* WITH GAS ENG

** WITH DIESEL ENG
8040d0f2 J968W-9
8W - 51 - 5
mm REAR LIGHTING
RIGHT LEFT LEFT

LICENSE LICENSE BACIC-UP
LAMP LAMP LAMP
(8W-51-4) C8W-51-4) (8W-51-7)
8050cd3c J968W-9
8W - 51 - i 8W-51 REAR LIGHTING BR
BATTERY
POWER
POSITIVE
AO 6RD- F U S E
C180 DISTRIBUTION
TERMINAL 2
CENTER
<8W-20-3,4) AO 6 R D * -
/
~ ^-^--)> 1
40A (2) A2
AO 12PK
AO
OOERD**
OERD AO B K
, S146
RIGHT 20BK*
BATTERY
ENGINE
POSITIVE
AO STARTER
TERMINAL
14PK** MOTOR
(WITH DIESEL
ENG) (8W-21-3 4)
(8W-20-4)
SPLICE
S148
(8W-70-21)
S201 BLOCK.
C241 8W-70-26
-)) A22 12BK/0R- -A22 12BK/OR
WITH
DRL
S120
8W-70-10
CONNECTOR C
•L10 20BR/LG—( •L10 18BR/LG-
C133
)) L10 22BR/LG—(£-
-L10 18BR/LG- L10

18BR
PARKV LG
NEUTRAL WITH
POSITION AUTO TRANS
C126
SWITCH
Cl€9 -~-^-^- C169
r l
L10
1 1 0
-LI 18VT/BK—<f=f#^^^T~)>— 18BR/LG- 18BR
,!_^T J LG
C126
(3) . 1 (1) WITH MAN
•LI 18VT/BK• BACK-UP TRANS
LAMP
LI SWITCH
18VT C161, -vC161
BK -LI 18VT/BK ^^#4-)>—L10 18BR/LG
1
( 1 )^ '(2)
•LI 18VT/BK •
C129 SPLICE
$117
-LI 18VT/BK• S313
•LI 18VT/BK•
8W-70-9 (8W-51-7)
-LI 18VT/BK •LI 18VT/BK - (8W-70-38)
WITH H I G H - L I N E
* WITH GAS ENG
CLUSTER
* * WITH DIESEL ENG
8050cd3d J968W-9
MM LIGHTING 8W - 51 - 7
C129
• L l 18VT/BK- L l 18VT/BK•
L l 18VT/BK - •Ll 18VT/BK

$313
WITH
HIGH-LINE 8W-70-38
CLUSTER
Ll
18VT
BK
Ll S117
18VT 8W-70-9
BK
Ll
18VT
BK
18BK
$402
8W-70-41
Z13
18BK
Ll
18VT $312 C329
BK 8W-70-38
^ €126 Z13 18BK- -Z13 18BK-
Ll
18VT
BK
WITH
TRAILER
Z13 Z13 TOW
WITH 16BK 12BK
't 1^- AUTO
TRANS
Ll
18VT Ll
18VT
BK BK $311
1 1 8W-70-37
1 1
BACK-UP PARK/
LAMP NEUTRAL
WITH
SWITCH POSITION TRAILER
(8W-51-6) SWITCH TOW
(8W-51-6) Z13 Z13
12BK 16BK
^ C128 ^ C128
Z13 Z13
16BK 12BK
f $115_
8W-70-8
I
Zl
16BK
8050cd3e
A G106
8W-15-6.7.8
J968W-9
8W - 51 - 8 8W-51 REAR LIGHTING mm
BATTERY
POWER
POSITIVE FUSE
— AO 6RD- C180 DISTRIBUTION
TERMINAL
CENTER
(8W-20-3,4) - AO 5RD* —
40A ( 6 )
AO
AO OOERD**
OERD AO
RIGHT 20BK*
A3
BATTERY 12RD
POSITIVE ENGINE
LG
TERMINAL AO STARTER
(WITH DIESEL 14PK** MOTOR
ENG) (8W-21-3.4)
(8W-20-4)
SPLICE
S148
(8W-70-21)
A3
12RD
WITH LG
$118 A3
DRL
• 8W-70-9 12RD
LG
A3
12RD
LG
S203
8W-70-27 C133
'A3 12RD/LG A3 12RD/LG- -<(- -A3 12RD/LG-
JOINT
CONNECTOR B
C231
— — F32 18PK/DB
SPLICE
S207
(8N-51-9)
(8W-70-29)
* WITH GAS ENG

** WITH DIESEL ENG
8050cd3f J968W-9
8W-51REAR LIGHTING 8W-51 - 9
STOP
LAMP
- L 5 0 18WT/TN-
SWITCH
(8W-51-8)
S207
8W-70-29 C202
•L50 18WT/TN- •L50 18WT/TN
L50
18WT
TN
C133
C183
— y
(3)
—L50 18WT/TN-
8W-70-34 C133
S218
-M2 20YL- -M2 1 8 Y L -
(2)
M2
20YL
(6) ^ C217 JOINT NO

COURTESY
LAMP CONNECTOR CONNECTION
DRIVER A
S149
8W-70-21
r~Ml 20PK- -Ml 20PK-

(1)
C133
Ml
20PK
S205
J 8W-70-28
Ml •Zl 20BK )
18PK (4) SEAT BELT
SWITCH
FUSE (8W-44-7)
BLOCK S115
! (17) 1>
^ C241 !
0 L8W-70-8
1 < 1
FUSE
17
j
;
15A !!
I; c Zl
18BK
> HOT A T A L L T I M E S <

G104 G301
8W-15-6 8W-15-14
8050cd40 J968W-9
8W-51 -1G 8W-51 REAR LIGHTING BR
FENDER AND TAILGATE LAMPS - DUAL REAR WHEELS
BATTERY
POWER
POSITIVE FUSE
AO 6RD- C180 DISTRIBUTION
TERMINAL 1
CENTER
(8W-20-3,4) AO 6 R D * -
50A (i) A7
AO 10RD
OOERD** BK
S147
RIGHT
8W-70-21
BATTERY
ENGINE
POSITIVE
STARTER
TERMINAL AO
MOTOR A7
(WITH DIESEL 14PK**
C8W-21-3.4) 12RD
ENG) BK
(8W-20-4) WITH
SPLICE POWER
SEAT » C133
S148 S204
(8W-70-21)
8W-70-28 A7
A7 1 2RD/BK — $ — A7 12RD/BK 12RD
BK
A7 12RD/BK-
FUSE • A7 12RD/BK-
BLOCK.
JOINT
CONNECTOR A
L
- F33 20PK/RD-
't f
Z13 Z13
16BK 12BK
C128 X C128
Z13 Z13 WITH

12BK 16BK TRAILER
I TOW
S311
8W-70-37
\ Z13
\
Z13 Zl
12BK WITH
16BK 12E
i I •TRAILER
TOW
S312
8W-70-38
-Z13 18BK
* WITH GAS ENG
-Z13 18BK ** WITH DIESEL ENG
8050cd41 J968W-9
BR- 8W-51 REAR LIGHTING 8W-51 11
BATTERY
POWER
POSITIVE
AO 6RD-
) — 1 I| ! FU
C180 SE
DISTRIBUTION
TERMINAL
CENTER
(8W-20-3,4) AO 6 R D * - 1 ' U ^ ^ ^ X ^ ^ ) —
s | 50A ( i )) A7
AO 10RD
OOERD** BK
$147
RIGHT
8W-70-21
BATTERY
ENGINE
POSITIVE
AO STARTER
TERMINAL
MOTOR A7
(WITH DIESEL 14PK**
(8W-21-3.4) 12RD
ENG) BK
(8W-20-4) WITH
SPLICE POWER
SEAT C133
S148 S204
(8W-70-21)
8W-70-28 A7
A7 1 2 R D / B K — f • A7 12RD/BK• 12RD
BK
A7 12RD/BK-
FUSE • A7 12RD/BK —
BLOCK
HEADLAMP
SWITCH CONNECTOR A
C206 C217
— L7 20BK/YL <(
1
• - F 3 3 20PK/RD—
$314
8W-70-39
L7
18BK
C128
$311 r- YL
-Z13 16BK
8W-70-37
-Z13 1 2 B K - ( f - Z 1 3 16BK-
C343
L7 L7
18BK 18BK
C128 L7 YL YL
**-Z13 12BK
7
Z13 1 6 B K - ( ( - Z 1 3 12BK- 18BK
YL
$312 WITH WITH S406

8W-70-38 TRAILER TRAILER S115 8W-70-42 C133
TOW TOW
8W-70-8
—Zl 16BK- L7 C129
Z13 18BK
18BK LEFT YL
G106
TAILGATE
8W-15-6,7,8 C406
LAMP L7 L7
C 44 224 4 ^ ^ C 4 2 4 18BK 18BK
C343
YL YL
Z13
^> 1 L7
18BK
(2) L7
18BK YL
Z13 18BK
18BK S408 YL $407 S106
8W-70-42 RIGHT L_ 8W-70-42 8W-70-4

$405 TAILGATE L7
I Z13
8W-70-42 1 1 3
18BK LAMP 18BK
18BK I C 4 2 5 ^ — V C425 YL
C406
-Z13 18BK- * WITH GAS ENG
n)\ /
mm0 (2) WITH DIESEL ENG
8050cd42 J968W-9
8W-51 -12 8W-51 REAR LIGHTING BR
SPLICE
S314 L E F T FORWARD
(8W-51-11) F E N D E R LAMP
(8W-70-39) C402 C420 C420 C402
L7 18BK/YL ({ L7 18BK/YL—(< *h»— Z13 18BK » Z13 18BK-
(2) (1)
R I G H T FORWARD
F E N D E R LAMP
C403 C421 C421 C4Q3

L7 1 8 B K / Y L - « 17 18BK/YL~<< •}—» - Z 1 3 18BK » Z13 18BK-
(2) (1)
LEFT REAR
F E N D E R LAMP
C404 C422 > ^ v C 4 2 2 C404

L7 1 8 B K / Y L - ^ f — L 7 18BK/YL-<< «|-))—"~ z l 3
18BK )) Z13 18BK-
(2) (1) S405
8W-70-42
S406
RIGHT R E A R
8W-70-42
F E N D E R LAMP
C405 C423 C423 C405

L7 1 8 B K / Y L - < ( — L 7 18BK/YL-(< >>-Z13 18BK—» Z13 18BK
(2) (1)
C343
Z13 18BK » Z13 18BK
S312
8W-70-38
1
Z13 Z13
f WITH
TRAILER
TOW
16BK 12BK
WITH
TRAILER
TOW
S311
8W-70-37
C128
S115
•Z13 1 6 B K - ^ < f Z13 12BK- 8W-70-8 G106
Zl 16BK J8W-15-6.7,
C128
•-Z13 12BK-(£-Z13 16BK-
8050cd43 J968W-9
BR 8W - 52 TURN SIGNALS 8W - 52 - 1
8W-52 ¥ U R H SIGNALS
D E S C R I P T I O N AMD O P E R A T I O N HAZARD FLASHERS

Circuit A15 from the battery positive post supplies
TURN SIGNALS power to the hazard flasher fuse (fuse C) in the
In the ACCESSORY or RUN position, the ignition Power Distribution Center (PDC).
switch connects circuit A l from fuse 3 in the Power Circuit L9 from the hazard flasher fuse supplies
Distribution Center (PDC) to circuit A31. Circuit A31 battery voltage to the hazard warning flasher. Circuit
feeds circuit L5 through fuse 6 in the fuse block. L19 from the flasher connects to the multi-function
Circuit L5 powers the turn signal flasher. Circuit switch.
L6 from the flasher connects to the multi-function When the operator presses the hazard flasher but
switch to supply power to the turn signals. The ton, the multi-function switch connects circuit L19 to
multi-function switch connects circuit L6 to the turn circuits L60, L61, L62, and L63.
signal lamps on circuits L60, L61, L62 and L63. Circuit L62 powers the right rear turn signal/stop
lamp. Circuit L63 powers the left rear turn signal/
RIGHT TURN SIGNAL stop lamp. Circuit L60 powers the right front lamps
When the operator selects the right turn signal, and circuit L61 powers the left front lamps.
the multi-function switch connects power from circuit Circuit L60 and L61 are double crimped at the
L6 to circuits L60 and L62. Circuit L62 feeds the multi-function switch and supply power for the turn
right rear turn signal/hazard flasher/stop lamp. signal indicator lamps in the instrument cluster.
Circuit L60 feeds the right front turn signal/hazard
flasher lamp and side marker lamp. Circuit L60 also GROUND CIRCUIT
splices to power the turn signal indicator lamp on the Circuit Z l provides a ground for the parking
instrument cluster. lamps, turn/tail/stop lamps, and rear license plate
lamps.
LEFT TURN SIGNAL Circuit Z l also provides a ground for the back-up
When the operator selects the left turn signal, the lamps and Center High Mounted Stop Lamps
multi-function switch connects power from circuit L6 (CHMSL) lamps.
to circuits L61 and L63. Circuit L63 feeds the left
rear turn signal/hazard flasher/stop lamp. HELPFUL INFORMATION
Circuit L61 feeds the left front turn signal/hazard • Check the 15 amp fuse located in cavity C of the
flasher lamp and side marker lamp. Circuit L61 also PDC
splices to power the turn signal indicator lamp on the • Check the ground locations for the lamps
instrument cluster.
GROUND CIRCUIT
Circuit Z l provides a ground for the parking lamps,
turn/tail/stop lamps, and rear license plate lamps. WIRING DIAGRAM INDEX
HELPFUL INFORMATION this section of the wiring diagrams. I f the component
® Check the 40 amp fuse located in cavity 3 of the you are looking for is not found here, refer to section
PDC 8W-02 for a complete list of all components shown i n
• Check the 15 amp fuse located in cavity 6 of the the wiring diagrams.
fuse block
• Check the lamp filaments
8W - 52 - 2 8W-52 TURN SIGNALS BR
DIAGRAM INDEX
Fuse 3 (PDC) 8W-52-3 Instrument Cluster 8W-52-5
Fuse 6 8W-52-3 Joint Connector B 8W-52-4
Fuse 6 (PDC) 8W-52-4 Park/Turn Signal Lamps 8W-52-6
Fuse C (PDC) 8W-52-3 Tail, Stop, and Turn Signal Lamps 8W-52-6
Hazard Warning Flasher 8W-52-3 Turn Signal/Hazard Switch 8W-52-5
Ignition Switch 8W-52-3 Turn Signal Flasher 8W-52-3
8050cd44 J968W-9
mm 8W-52 TURN SIGNALS BW - 52 - 3
BATTERY
$148
POSITIVE
TERNINAL
<8W-20-3,4)
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH DIESEL ENG)
(8W-20-4)
* WITH GAS ENG

** WITH DIESEL ENG
8050cd45 J968W-9
8W^52~4- 8W-52 TURN SIGNALS • BR
POWER
DISTRIBUTION
BATTERY FUSE 6_C180 CENTER
POSITIVE
TERMINAL
40A (6)
(8W-2Q-3 4)P
A3
RIGHT 12RD
BATTERY LG
POSITIVE
TERMINAL AO AO
(WITH DIESEL OOERD** 14PK**
ENG)
(8W-20-4)
ENGINE SPLICE WITH

STARTER S148 DRL
A3
MOTOR (8W-52-3) L2RD
(8W-21-3.4) (8W-70-21) LG
A3 $118
12RD 8W-70-9
LG
A3
1.2RD
LG
FUSE S203
BLOCK 8W-70-27!
C 2 4 1 FUSE 20 €241 C133
H ^ H § )> •A3 12RD/LG- •A3 1 2 R D / L G ~ < ( - — A 3 12RD/LG —'
(20) 15A (16)
STOP
LAMP
F32 SWITCH
18PK
DB
JOINT
CONNECTOR B
C231 C231 S207

-F32 18PK/DB <( ))L-L50 18WT/TN- 8W-70-29
(5)
<f
(4) L50
18WT
TN
TURN S I G N A L /
HAZARD SWITCH
(8W-52-5)
* WITH GAS ENG

** WITH DIESEL ENG
8050cd46 J968W-9
BR- 8W-52 TURN SIGNALS 8W-52-5
S T O P LAMP
] INSTRUMENT TURN HAZARD SWITCH
! LT RT SIGNAL C8W-52-4)
• CLUSTER WARNING L50
» TURN TURN
FLASHER FLASHER 18WT
SIGNAL SIGNAL
i
C8M-52 3 ) (8W-52-3) TN
| S207
(12): (14) C216
8W-70-29
I
L6 L19
L50
20RD 18PK
18WT
L60 GY WT
TN
20TN
BK (17) : (13) C210 (14) : C210
r. i . i
TURN
L61 C210 HAZARD SWITCH SIGNAL/
20LG
HAZARD
YL
r !(n J NORMAL i i A
SWITCH
(PART OF
H AZ A R D ^ - ^ f f f MULTI
FUNCTION
I•1
(16)
5O B
TURN
I
TURN
RIGHT
SWITCH)
LEFT
L60 L61 (15) ^ C210

18TN 18LG
BK YL L63 L62
18DG 18BR
RD PK
C133 " . €129
—(£-—L62 18BR/PK ))—
C133*,
C133 C133 L63

18DG L62
RD 18BR
PK
C129
1
L60 L61 -)>-L63 18DG/RD
20TN 20LG
BK YL
f" WITH f WITH 1
1^—TRAILER Ut— TRAILER

L63 TOW L62 TOW
S102 S123 18DG 18BR
RD
8W-70-3 8W-70-11 L63 i S316 L62 P
! K
S31S
18DG 8W-70-39 18BR
8W-70-39
RD PK
L63 L62
18DG 18BR
RD PK
L60 L61
18LG 18LG C333 C333 C329 C329
TN TN
L63 L62 L62
L63
18DG 18DG 18DG
18DG
BR BR BR
BR
RIGHT
PARK/
LEFT
PARK/
L
LEFT TAIL.STOP
J L
RIGHT T A I L . S T O P
AND T U R N - AND T U R N
TURN TURN
S I G N A L LAMP .. S I G N A L LAMP
SIGNAL SIGNAL
(8W-52-6) (8W-52-6)
LAMP LAMP
(8W-52-6) (8W-52-6)
8050cd47 J968W-9
8W-52-6- 8W-52 TURN SIGNALS BR
$401
L63 18DG/RD-
$316
#—L63 18DG/RD-
L63
18DG
RD
^ C129
L63
18DG
RD
C133
L63
18DG
RD
TURN
TRAILER SIGNAL/
TOW HAZARD
(8W-54-4) SWITCH
8W-52-5)
L62 L62
18BR 18BR
Z13 Z13 RIGHT T A I L . PK PK
12BK 16BK 8W-70-41 C415
S T O P AND
1 1 -Z13 18BK (<
TURN S I G N A L €331 C133
^
Z13
16BK
1
C128
f1
Z13
12BK
€128 (1)
C415
LAMP
L62
18BR
PK
L62
18BR
PK
C129
WITH
TRAILER
$115 S315 L62
TOW
18BR
8W-70-8 8W-70-39
PK
•L62 18BR/PK- -L62 18BR/PK-
Zl
16BK
6106 -L62 18BR/PK-
8W-15-6.7.8
LEFT SPLICE RIGHT
PARK/TURN $123 PARK/TURN
SIGNAL (8W-52-5) SIGNAL
LAMP C8W-70-11) LAMP
C112 C112 €101 C101
•Zl 18BK J
<>— L 6 1 1 8 L G / T N - L60 18LG/TN
(1) (3) $103 (i) (3)
8W-70-3
•Zl 18BK- •Zl 18BK- SPLICE

""NT
(3^_Clf3 Zl
i $102
(8W-52-5)
GROUND 18BK C8W-70-3)
GND G102
JOINT
[8W-15-4I
8050cd48 J968W-9
BR 8W • §3 WIPERS 8W • 53 - 1
8W-53 WIPERS
DESCRIPTION AND OPERATION trol module powers the park switch in the wiper
motor on circuit V5.
WIPERS The intermittent windshield wiper system is also
Fuse 8 in the fuse block powers the intermittent equipped with a pulse wipe feature. To activate this
wiper system. The intermittent wiper system oper feature, the operator presses the washer switch
ates at either DELAY, LOW or HIGH speeds. momentarily. When the washer switch CLOSES, volt
In the ACCESSORY or RUN position, the ignition age from circuit V6 passes through the switch to cir
switch connects circuit A l from fuse 3, a 40 amp, in cuit V10. Circuit V10 provides a signal to the
the Power Distribution Center (PDC) with circuit intermittent wiper control module and supplies volt
A31. Circuit A31 supplies voltage to circuit V6 age for the windshield washer pump. When the con
through fuse 8 in the fuse block. trol module receives the signal on circuit V10, i t
Circuit V6 splices to supply power to the wiper cycles the wipers on circuit V3 while the washer fluid
switch circuitry in the multi-function switch, the pump operates.
intermittent wiper control module and the park The washer motor operates whenever the washer
switch in the wiper motor. Ground for the wiper switch CLOSES and supplies voltage to i t on circuit
motor is supplied on circuit Z l . Circuit Z3 provides V10. Circuit Z l provides ground for the pump motor.
ground for the intermittent wiper control module.
When the operator moves the wiper switch to the HELPFUL INFORMATION
LOW speed position, the switch passes voltage to cir • Circuit V3 is double crimped at the multi-func
cuit V3. Circuit V3 feeds the wiper motor LOW speed tion switch to allow either the wiper switch or inter
brushes. I f the operator selects wiper HIGH speed mittent wiper control module to power the wiper
operation, the wiper switch passes current to circuit motor LOW speed brushes
V4. Circuit V4 feeds the wiper motor HIGH speed • Check the 40 amp fuse located in cavity 3 of the
brushes. PDC
If the operator selects wiper DELAY operation, the • Check the 20 amp fuse located in cavity 8 of the
wiper switch provides an input to the intermittent fuse block
wiper control module on circuit V9. The DELAY por
tion of the wiper switch contains a variable resistor. LOW WASHER FLUID WARNING LAMP
The variable resistor connects to the intermittent The low washer fluid warning lamp is located in
wiper module on circuit V9. Voltage for the resistor is the instrument cluster. Circuit G29 connects the
supplied by circuit V6 through the wiper switch. The warning lamp to the low washer fluid sensor in the
amount of delay selected by the operator determines washer fluid reservoir. The switch in the sensor
the voltage drop through the resistor and the voltage CLOSES when the fluid level drops below a cali
level received by the intermittent wiper control mod brated level. When the switch CLOSES, voltage flows
ule. through the warning lamp to ground on circuit Z l .
Circuit V8 is also an input to the intermittent
HELPFUL INFORMATION
wiper control module. This input is used by the mod
• Check the grounding location for the sensor
ule as a delay ON input.
• Check the continuity across the switch
After the intermittent wiper control module deter
mines the amount of delay selected, i t cycles the wip
ers by periodically energizing circuit V I 7 which SCHEMATICS AND DIAGRAMS
connects to circuit V3 through the wiper switch. Cir
cuit V3 powers the wiper motor LOW speed brushes. WIRING DIAGRAM INDEX
As the windshield wiper motor turns, the park The following index covers all components found in
switch, internal to the motor, moves from its this section of the wiring diagrams. I f the component
grounded position (down) to the powered RUN (up) you are looking for is not found here, refer to section
position. Circuit V7 provides an input to the inter 8W-02 for a complete list of all components shown i n
mittent wiper control module when the wiper switch the wiring diagrams.
is in the OFF position. The intermittent wiper con
DIAGRAM INDEX
Fuse 3 (PDC) 8W-53-3, 4 Intermittent Wiper Switch 8W-53-3
Fuse 8 8W-53-3, 4 Low Washer Fluid Switch .. 8W-53-4
Ignition Switch 8W-53-3, 4 Windshield Washer Pump Motor 8W-53-4
Instrument Cluster 8W-53-4 Windshield Wiper Motor 8W-53-4
Intermittent Wiper Control Module 8W-53-3, 4
8050cd49 J968W-9
BR 8W-53 WlPEiS 8W - 53 - 3
POWER
POSITIVE
CENTER
TERMINAL
(8W-20 3,4) Al 12RD
AO AO AO
OERD 20BK* 6RD*
I I
AO AO
14PK** OOERD**
RIGHT SPLICE ENGINE

BATTERY S148 STARTER
POSITIVE (8W-70-2U MOTOR
1
TERMINAL (8W-21-3,4)
(WITH DIESEL
ENG)
(8W-20-4)
INTERMITTENT WIPER SWITCH

(PART OF MULTI-FUNCTION SWITCH)
HIGH A niiai
O F F ^ LOW* k HIGH O F F > ^ LOW®

DELAY • •TDELAY •
OFF>< LOW*""
• DELAY
(7): (8): (6): (5) (2):
V3 V4 WINDSHIELD
18BR 16RD WASHER
WT YL PUMP MOTOR
I (8W-53-4)
^ C133
V4
18RD
V7 YL VIO
V17
18DG I 18BR
WT 18DG
f J
WINDSHIELD WINDSHIELD ^ filM
WIPER WIPER
MOTOR VIO V6 18DB/BK
MOTOR
18BR
(8W-53-4) (8W-53-4)
L_
C219 WINDSHIELD
WIPER
6 7 1 8 3 2 INTERMITTENT
MOTOR
WIPER WIPER WIPER WIPER FUSED WIPER WIPER
(8W-53-4)
PARK SW SW SW IGNITION SW CONTROL
SW DELAY MODE MODE SW MODE MODULE
SENSE OUTPUT SIGNAL GND SIGNAL OUTPUT SIGNAL
5 (ACC/RUN)
» C219
S 2 0 g
18BK
OR I8W-70-29 G201
|—Z3 12BK/OR 8W-15-13
* WITH GAS ENG
** WITH DIESEL ENG
8050cd4a J968W-9
8W.- 53^4 8W-53 WIPERS BR
POWER
POSITIVE i ' FUSE CENTER
TERNINAL AO 6RD—^^^Mj-I FUSE C180
C8W-20-3,4) • A l 12RD-
(3)
C133
i 40A
AO Al
AO 6RD* 12RD
AO 20BK* 1
OERD 1 AO INSTRUMENT | S124
RIGHT AO OOERD** WASH CLUSTER 8W-70-12
14PK** FLUID I
BATTERY 1 • Al
POSITIVE
TERMINAL
(WITH D I E S E L
1
SPLICE
\ ENGINE
STARTER
SW
SENSE
(7)
12RD
(7) ^ C215 C212

ENG) S148 MOTOR IGNITION
(8W-2Q-4) G29
C8W-70-21) C8W-21-3,4) 22BK/TN SWITCH
START ACC
SI 0 8 V U N \ ^ ,
• Z l 12BK 8W-70-5 LOW WASHER ^ C133
GIOI G29
FLUID SWITCH ^JÔFF
8W-15-3 18BK/TN
C108 C108
WINDSHIELD
WIPER MOTOR
1
— Z l 18BK-<(4-#
(2)V^ (1)
C133
J WITH SPEED
CONTROL,
H I G H - L I N E CLUSTER
(6)
T
C212
C124 A31
•V6 18DB/BK •V6 18DB/BK-
WIPERS r PARK
UP # SWITCH
^y C133
12BK
WT
- V5 18DG/YL - ) > — V5 18DG/YL -

(3)1 FUSE
(2)! (39) C241
•LOW
BLOCK
WIPERS
DOWN V3
C133
V3 _
-18BR—»—18BR-^ INTERMITTENT FUSE
WT WT 8
(4) 1
WIPER
HIGH V4 I V4 SWITCH 20A
—))H.8RD—))—16RD—« (8W-53-3) (44): C241
YL YL
(1) S103
V6
8W-70-3 16DB
Zl 20BK- BK
BLACK 1 S202
8W-70-27
Zl
18BK
1 _ S115 V6
8W-70-8 18DB
BK
I
Zl
16BK G106 -X C219
A' 8W-15-6
VIO
18BR
i 4
J WIPER
3
FUSED
!
;
INTERMITTENT
WIPER
CONTROL
• SW MODE I G N I T I O N i
SENSE SW j MODULE
OUTPUT ,
! WIPER ( A C C / R U N ) j
CI33
J
! SW MODE
SIGNAL GND |
2 5
1 i
INTERMITTENT ^ C219
WIPER SWITCH -VIO 18BR-
Z3
G201 (8W-53-3) 18BK
8W-15-13 -V10 18BR- OR
•Z3 12BK/0R-
* WITH GAS ENG
S206 * * WITH D I E S E L ENG
8W-70-29
8050cd4b J968W-9
BR 8W - 54 TRAILER TOW 8W - 54 -1
8W-54 TRAILER TOW
DIAGNOSIS A N D TESTING • A6 for a battery feed

• L76 for a battery feed from the trailer tow relay
TRAILER TOW for the park, license, and side marker lamps
The trailer tow package consists of a relay located • L l as a back up lamp input
in the Power Distribution Center (PDC), a trailer tow • L62 for the right turn signal/stop lamp
connector, and an electric brake provision. • L63 for the left turn signal/stop lamp
• Z13 for a ground
TRAILER TOW RELAY • B40 for the electric brake provision
The trailer tow relay located in the Power Distri
bution Center (PDC) is supplied power for the con HELPFUL INFORMATION
tact side on circuit A6. This circuit is protected by a • Check the 30 amp fuse located in cavity 7 of the
30 amp fuse located in cavity 7 of the PDC and PDC
spliced to provide power to the trailer tow connector. • Check the grounding location for circuit Z13.
Power for the coil side of the relay is supplied on
circuit L7. This circuit is HOT when the headlamp
SCHEMATICS A N D DIAGRAMS
switch is in the PARK or ON position. Ground for the
coil side of the relay is supplied on circuit Z l .
When the relay is energized, the contacts in the
relay CLOSE connecting circuits A6 and L76. Circuit
L76 connects from the relay to the trailer tow con
nector.
TIAILER TOW C0I1ECT0R
The following circuits connect to the trailer tow
connector:
8W~54-2 = 8W-54 TRAILER TOW BR
DIAGRAM INDEX
Fuse 7 ( P D C ) . . . . . . . . . . . . . . . . . . 8W-54-3 Trailer Tow .....8W-54-4
Joint Connector A 8W-54-3 Trailer Tow Relay 8W-54-3
Trailer Brake Provision . . . . . . . . . . . . . . . . . . . . . 8W-54-4
8050cd4c J968W-9
BR 8W-54 TRAILER TOW 8W - S4 - 3
BATTERY
SPLIGE
POSITIVE AO 2 0 B K * - -AO 14PK**- S148
TERMINAL
(8W-70-21)
(8W-20-3.4)
RIGHT
BATTERY
POSITIVE
TERMINAL
(WITH
DIESEL
ENG)
(8W-20-4)
ENGINE
STARTER
MOTOR
(8W-21-3.4)
POWER
T R A I L E R TOW DISTRIBUTION
RELAY CENTER
FUSE
it
7 C180 C180
# 40A
1(30) C129
(7): €180
11 (87)
»r—L76 12BK/0R-
A6
12RD
TN -)^-Zl 20BK- L76
12BK
(86) (85) OR
S108
8W-70-5
A6 S106
12RD L7 20BK/YL- 8W-70-4
TN Zl
C332
S119 12BK
L7
A6 8W-70-9 18BK
12RD G101
YL
TN
A6 m 8W-15-3
12RD
C133
TN
L76
12BK
C129 L7
+
A6
18BK
YL
OR
12RD
TN
(4) ^ C217
ELECTRIC C332 JOINT

"""PARK""
B R A ICE LAMP CONNECTOR TRAILER
PROVISION A6 SWITCH TOW
(BOTTOM 12RD OUTPUT (8W-54-4)
TN
LEFT
OF I . P . )
TRAILER
TOW
** WITH DIESEL ENG
8050cd4d J968W-9
8W - 54 - 4 8W-54 TRAILER TOW BR
T i l l SIGNAL/ TRAILER mm SPLICE TURN

H A Z A R D SWITCH RELAY S119 SIGNAL/
C8W-S2-S) C8W-54-3) (8W-54-3) HAZARD
C8W-70-9) SWITCH
C8W-52-5)
L63
18DG
RD A6
L62
12RD 18BR
TN
PK
X C133
L63
18DG
C129
T
RD L62
18BR
[( A6 12RD/TN—' PK
C129
C129
L63
18DG
+
L62
RD
18BR
S316 PK S31S
8W-70-39
8W-70-39
L63 L62
18DG 18BR
RD PK
C331 C331
- » L63 18DG/RD L62 18BR/PK-
PARK/
BACK-UP NEUTRAL
LAMP POSITION
SWITCH SWITCH
(8W 51-6) (8W-51-6)
!
Ll
!
Ll
18VT 18VT
BK BK
B40 1 4 L B -
C128
Ll
18VT B40
BK 14LB
TRAILER
TRAILER
i BRAKE
TOW i
0 U T P U T i
i PROVISION
Zl 16BK ilis
8W-15-6,7.8
8050cd4e J968W-9
8W - 60 POWER WINDOWS 8W - 60 - 1
8W-60 POWER WINDOWS
DESCRIPTION AND OPERATION Grounding is provided on circuit Q12 from the motor
back to the right switch.
POWER WINDOWS The ground is passed through the switch on a bus
The power window system is supplied power from bar to circuit Q16. Circuit Q16 then connects to the
the 30 amp circuit breaker located in the fuse block. master switch. The ground is passed through the
Power for the circuit breaker is supplied on circuit switch to ground on the Z3 circuit.
A22 from the ignition switch. This circuit is HOT When window UP operation is selected, the power
when the ignition switch is in the RUN position. and ground circuits are reversed. Circuits Q16 and
Power for the A22 circuit is supplied by the A2 cir Q12 are the feeds and circuits Q22 and Q26 are the
cuit which is HOT at all times and protected by a 40 grounds.
amp fuse located in the Power Distribution Center
(PDC), cavity 2. RIGHT WINDOW SWITCH OPERATION
Circuit F21 connects from the circuit breaker to When the window switch is moved to the window
both window switches. Circuit F21 is the feed for the DOWN position, voltage is supplied on the F21 cir
switches. Both switches use a bus bar to provide cuit through the CLOSED contacts in the switch to
power for the different functions of the switch. the Q22 circuit. The Q22 circuit connects from the
The ground path for the system is through the switch to the right front window motor. Grounding is
master window switch on the Z3 circuit. provided on circuit Q12 from the motor back to the
switch. The ground is passed through the switch to
MASTER WINDOW SWITCH (LEFT WINDOW the Q16 circuit. The Q16 circuit connects from the
OPERATION) right switch to the master switch. Ground is passed
When the window switch is moved to the window through the master switch to ground on the Z3 cir
DOWN position, voltage is supplied on the F21 cir cuit.
cuit through the CLOSED contacts in the switch to When window UP operation is selected, the power
the Q21 circuit. The Q21 circuit connects from the and ground circuits are reversed. Circuit Q12 is the
switch to the left front window motor. Grounding is feed and circuits Q22 and Q26 are the ground.
provided on circuit Q l l from the motor back to the
switch. The ground is passed through the switch to HELPFUL INFORMATION
ground on the Z3 circuit. • Check the 40 amp fuse located cavity 2 of the
When window UP operation is selected, the power PDC
and ground circuits are reversed. Circuit Q l l is the • Check the 30 amp circuit breaker located in the
feed and circuit Q21 is the ground. fuse block
• Check the ground for the power window system
MASTER WINDOW SWITCH (RIGHT WINDOW
OPERATION)
When the window switch is moved to the window SCHEMATICS AND DIAGRAMS
DOWN position, voltage is supplied on the F21 cir
cuit through the CLOSED contacts in the switch to WIRING DIAGRAM IN0EX
the Q26 circuit. The Q26 circuit connects from the The following index covers all components found in
master switch to the right window switch. A bus bar this section of the wiring diagrams. I f the component
internal to the right switch passes the voltage you are looking for is not found here, refer to section
through the switch to circuit Q22. Circuit Q22 con 8W-02 for a complete list of all components shown in
nects from the switch to the right window motor. the wiring diagrams.
8 W . 60 .2 8W-60 POWER WINDOWS
DIAGRAM INDEX
Component Page Component
Circuit Breaker 1 8W-60-3, 4 Left Power Window Switch
Fuse 2 8W-60-3, 4 Right Power Window Motor
Ignition Switch 8W-60-3, 4 Right Power Window Switch
Left Power Window Motor 8W-60-3
8050cd4f
8W-60 POWER WINDOWS 8W - S i - 3
POWER
DISTRIBUTION
CENTER
BATTERY
POSITIVE
TERNINAL
<8W-20-3,4)
C133
RIGHT
BATTERY AO AO AO j w~ —t—A2 1 2 P K / B K -
POSITIVE OERD 20BK* 6RD* i
1 ! S146
TERMINAL 1 1
(WITH D I E S E L
AO AO i 8W-70-20 |
14PK** OOERD** I i
ENG)
(8W-20-4) t t
SPLICE ENGINE
S148 STARTER
(8W-70-21) MOTOR
(8W-21-3.4)
FUSE
S201
S214 BLOCK
C241 CB1 C241 8W-70-26 (5)
8W-70-32
o •F21 14TN •
(8) 30A (7)
>>-A22 1 2 B K / 0 R - — A22 1 2 B K / O R — 1
F21
14TN OPTIONAL
V €347 RIGHT RIGHT
— F21 14TN-* < f - F 2 1 14TN POWER POWER
C207
WINDOW WINDOW
—<f-F21 14TN SWITCH SWITCH
LEFT - F 2 1 14TN- (8W-60-4) (8W-60-4)
POWER WINDOW
SWITCH
C316
016 Q26
F21 14TN-
14BR 14VT
LEFT WT WT
POWER WINDOW
MOTOR
l OPTIONAL
C318
Q16 Q16 Q26

14BR 14BR 14VT
WT WT WT
^ C346 C346
C207 C239 Q16 Q26 026

14BR 14VT 14VT
1—016 1 4 B R / W T — ) ) — Q16 14BR/WT—(£-
WT WT WT
C348 C207
*k C239
i—016 14BR/WT-)>-Q16 14BR/WT—•))- 01
TJ
I C348 C207 C239
Q26 14VT/WT~»-Q26 14VT/WT-)) -Q26 14VT/WT-
C207 C239
•Q26 14VT/WT- -)) 026 14VT/WT-
Z3 14BK/0R-
Z3 14BK/0R G302
C347
8W-15-14
B*»— Z3 1 4 B K / 0 R — ) > - Z 3 14BK/0R-
/
OPTIONAL * WITH GAS ENG
8050cd50 J968W-9
8W-60-4 8W-60 POWER WINDOWS BM
POWER
DISTRIBUTION
CENTER
BATTERY FUSE 2 ^
POSITIVE AO 6RD
TERNINAL 40A (2) A2
<8W 2 0 - 3 , 4 ) 12PK
BK
RIGHT C133
BATTERY AO AO AO • A2 1 2 P K / B K - ) ) ,
POSITIVE OERD 20BK* 6RD* A2
_J I S146
T E R N I N A L •* I
(WITH DIESEL AO AO 8W-70-20
ENG) 14PK** OOERD**
C8W-20-4) t t
SPLICE ENGINE
S148 STARTER
(8W-70-21) NOTOR
(8W-21-3,4)
FUSE
S214 BLOCK
(5) C212
1
F21 1 4 T N - — A22 12BK/OR—
OPTIONAL
\ C345
C239 •F21 1 4 T N - * — ( £ - F 2 1 14TN-
<(-F21 14TN-*-
F21 14TN-1
-F21 14TN-
R I G H T POWER
C207 C239 WINDOW S W I T C H
—» 016 1 4 B R / W T — ( f - Q 1 6 14BR/WT-
C239 C346 5—016 14BR/WT—{{•
|—(f-Q16 14BR/WT~<f--Q16 14BR/WT-
Q16 Q16
OPTIONAL
1 4 B R U
WT w f . C346
Q 2 6 1 4 V T / W T
^ mm •| «~ -
016 026 •Q26 14VT/WT-^4
14BR 14VT
WT
Q16
^ C348
WT
026
C239 X
Y
Q26
026
C239
14VT/WT-
14BR 14VT 14VT

WT WT WT
^ C207 ^ C207
026 Q26
14VT 14VT
Q16 WT WT
14BR
WT ^ C348
026 L E F T POWER
14VT WINDOW
L E F T POWER WT -026 14VT/WT-
SWITCH
WINDOW
C8W-60-3)
SWITCH
(8W-60-3)
* WITH GAS ENG
** WITH DIESEL ENG
8050cd51 J968W-9
BR 8W - 81 POWER POOR. LOCKS 8W - 61 -1
8W-61 POWER DOOR L O C K S
DESCRIPTION AND OPERATION RIGHT DOOR SWITCH OPERATION (LOCK)

When the switch is moved to the LOCK position,
POWER DOOR LOCKS voltage is supplied to the P33 circuit, and then to the
Circuit A7 from fuse 1 i n the Power Distribution door lock motors. The ground path is provided on the
Center (PDC) powers circuit F35 through fuse 19 i n P34 circuit back to the right door switch. The ground
the fuse block. Circuit F35 supplies power to both is passed through the switch internal bus bar to the
door lock switches. P36 circuit. The P36 circuit connects to the left door
The ground path for the system is through the left switch and through to ground on circuit Z3.
door lock switch on the Z3 circuit.
RIGHT DOOR SWITCH OPERATION (UNLOCK)
LEFT DOOR SWITCH OPERATION (LOCK) When the switch is moved to the UNLOCK posi
When the door lock switch is moved to the LOCK tion voltage is supplied to the P34 circuit from the
position, voltage is supplied on the P35 circuit to the switch to the door UNLOCK side of the motors. The
bus bar located inside the right door switch, LOCK grounding path is through the LOCK side of the
side. Battery voltage is passed through the switch to motors, circuit P33, back to the switch. The ground
the door motors on circuit P33. Grounding is pro continues through the internal bus bar of the switch
vided through the P34 circuit for both door motors on circuit P35 to the left door switch. At the left door
back to the right door switch. The ground is passed switch, the ground passes through that switches
through the bus bar internal to the switch, UNLOCK internal bus bar to ground on circuit Z3.
side, to the P36 circuit. The P36 circuit connects to
the left front switch to a bus bar, internal to the HELPFUL INFORMATION
switch, and then to the Z3 circuit. The Z3 circuit pro • Check the 50 amp fuse in cavity 1 of the PDC
vides ground. • Check the 20 amp fuse i n cavity 19 of the fuse
block
LEFT DOOR SWITCH OPERATION (UNLOCK) • Check the grounding point for the door lock
When the switch is moved to the UNLOCK posi switch
tion, voltage is supplied on the P36 circuit to the
right door switch, UNLOCK side. The battery voltage
is passed through the switch internal bus bar to the
P34 circuit. The P34 circuit then connects to the door
WIRING DIA6RA1 INDEX
motors on the UNLOCK side. Grounding for the
UNLOCK function is provided by the P33 circuit. The following index covers all components found i n
The P33 circuit connects back to the right door this section of the wiring diagrams. I f the component
switch, LOCK side, and passes through the internal you are looking for is not found here, refer to section
bus bar to the P35 circuit. The P35 circuit connects 8W-02 for a complete list of all components shown i n
back to the left door switch, and passes through the the wiring diagrams.
switch to ground on circuit Z3.
8 W . 6 1 .2 — • 8W-61 POWER DOOR LOCKS —
DIAGRAM INDEX
Fusel (PDC). 8W-61-3, 4 Left Power Door Lock Switch
Fuse 19 8W-61-3, 4 Right Power Door Lock Motor
Left Power Door Lock M o t o r . . . . . . . . . . . . . . . . 8W-61-5 Right Power Door Lock Switch
8050cd52
BR 8W-61 POWER DOOR LOCKS SW - 61 - 3
S2§4
BATTERY
POSITIVE
TERNINAL
(8W-20-3,4>
RIGHT
BATTERY
POSITIVE
TERNINAL
(WITH
DIESEL
ENG)
(8W-20-4)
ENGINE
^ STARTER
NOTOR
(8W-21-3,4)
* WITH GAS ENG

** WITH DIESEL ENG
8050cd53 J968W-9
8W - 61 - 4 8W-61 POWER DOOR LOCKS BR
BATTERY
POSITIVE
TERNINAL
(8W~20-3,4)
RIGHT
BATTERY
POSITIVE
TERNINAL WITH
( W I T H DIESEL POWER
ENG) SEAT
(8W-20-4)
ENGINE
STARTER
NOTOR
C8W-21-3.4)
SPLICE
S3ii
C8W-61-5)
C8W-70-37)
•P33 160R/BK * WITH GAS ENG

** WITH DIESEL ENG
8050cd54 J968W-9
8W-61 POWER DOOR LOCKS 8W - 61 - 5
RIGHT POWER
DOOR LOCK MOTOR RIGHT POWER
RIGHT POWER
DOOR LOCK. n P34 16PK/BK-
DOOR LOCK
SWITCH
SWITCH
(8W-61-4)
(8W-61-4)
L E F T POWER
P33 P3'4
DOOR LOCK MOTOR
160R 16PK
BK BK
8050cd55 J968W-9
BR 8W - 62 POWER MIRRORS 8W - 62 - 1
8W-62 POWER MIRRORS
DESCRIPTION AND OPERATION through' circuit P70. When the DOWN movement is
selected, the power and ground are reversed.
POWER MIRRORS I f a RIGHT door mirror movement LEFT is
The power mirrors use a single switch located in selected, voltage is supplied through the P74 circuit
the left door trim panel. The feed for the system is and the ground is passed through circuit P70. When
supplied on circuit M l from the 15 amp Ignition-Off the left door mirror RIGHT movement is selected,
Draw (IOD) fuse located in the fuse block cavity 17. the power and ground are reversed.
This fuse also supplies power for the radio, interior
lamps and other components. Grounding for the HELPFUL INFORMATION
power mirrors is provided through the Z3 circuit. • Check the IOD fuse located i n the fuse block
• Circuit M l supplies voltage to the radio, cargo
SWITCH AND MIRROR OPERATION lamp, dome lamp, time delay relay, glove box lamp,
The power mirror switch has a right and a left and vanity lamps. Check for proper operation of
position. Moving the switch to either of these posi these items
tions changes the voltage path internal to the switch • Move the switch to its various positions and lis
(changes polarity at the motors). ten for the motors to click or try to move. Some
When the switch is moved to the LEFT position movement or clicking indicates a poor connection or a
and mirror movement UP is selected, voltage is sup mechanical problem with a mirror
plied through the P75 circuit and the ground path is • Check the ground for the power mirror switch
through circuit P73. When the DOWN movement is
selected, the power and ground are reversed.
If a LEFT door mirror movement LEFT is selected, SCHEMATICS AND DIAGRAMS
voltage is supplied through the P71 circuit and the
ground is passed through circuit P73. When the left WIRING DIAGRAM INDEX
door mirror RIGHT movement is selected, the power The following index covers all components found in
and ground are reversed. this section of the wiring diagrams. I f the component
When the switch is moved to the RIGHT position you are looking for is not found here, refer to section
and mirror movement UP is selected, voltage is sup 8W-02 for a complete list of all components shown i n
plied through the P72 circuit and the ground path is the wiring diagrams.
8W - 62 - 2 — — — — 8W-62 POWER MIRRORS BR
DIAGRAM INDEX
Fuse 1 (PDC) 8W-62-3 Power Mirror Switch 8W-62-3
Fuse 17 8W-62-3 Right Power Mirror Motors 8W-62-3
Left Power Mirror Motors 8W-62-3
8050cd56 J968W-9
mm- —~ - — — - 8W-62 POWER MIRRORS" • —ill -62-3
POWER
DISTRIBUTION
CENTER
BATTERY FUSE 1 C 1 8 0
POSITIVE
TERNINAL 50A » - A7
(1)
(8W-20-3.4) 10RD
BK
RIGHT I
S147
BATTERY AO AO AO -A7 12RD/BK• 8W-70-21
OERD 20BK* 6RD*
POSITIVE
TERNINAL * I I : C133 WITH
(WITH DIESEL AO AO POWER
14PK** OOERD**
ENG) SEAT
A7 S204
(8W-20 4 )
. SPLICE
S148
12RD
BK A7
-12RD-
8W-70-28
A7
•12RD
Li
ENGINE (8W-70-21) BK BK FUSE
STARTER BLOCK
k l
NOTOR -12RD-
(8W-21-3.4) BK
1
C347 C201 S205
-Ml 20PK- - M l 20PK » — 8W-70-28
-Ml 20PK- - M l 18PK-
(4) C310 POWER N I R R O R S W I T C H
C310
)) •13 18BK/0R-
(8)
DN- LT- RT
7~
WITH /
L
Z 3 Z3
LEFT RIGHT POWER ' 14BK 18BK
MIRROR MIRROR WINDOWS OR S306 OR
U K
AND i
(5) (2): (7) (3) (1): C310 LOCKS 1 8W-70-36
Y----Y-- Y i
P75 P72 P73 P70 P71 P74 Z3 1
20WT 20YL 20DB 14BK C347

20DB 20YL 20YL
WT BK PK OR
^ C34J 4^ C34Z* ^ C34Z* Z3
Z3 18BK
P74
14BK OR
P70 20DB
20WT ^ C201 OR
L E F T POWER
N I R R O R NOTORS R I G H T POWER
C201 N I R R O R NOTORS
20DB
VERTICAL
O i l C311 P70 ^ C240 VERTICAL G302
C347«
(1) O
UP
N
-—' nw
(2)
20WT
^ C240
P74
20DB
1C345*
C322
(3) IIP
N
—' nw
8W-15-14
P70
P72
(3) O v _ x
20WT
^ C345*
P74
20DB
P72
f t 1) 0
LT
v
^ RT
C322
(2)
L T R T 1 T DT
20YL HORIZONTAL P70
20YL
BK HORIZONTAL BK 20WT
C201 C240 C345 1 -A-

-P72 20YL/BK- -((—P72 20YL/BK—<f-
• WITH OPTIONAL
* WITH GAS ENG
* * WITH DIESEL ENG
8050cd57 J968W-9
BR 8W - 63 POWER SEAT 8W -63-1
8W-63 P O W E R S E A T
DESCRIPTION AND OPERATION through the CLOSED contacts in the switch to the
P15 circuit. The P15 circuit connects to the motor.
INTRODUCTION Ground is provided on the P17 circuit back to the
The power seat system is protected by a 30 amp switch. A ground bus bar internal to the switch then
circuit breaker located in cavity CB2 of the fuse connects to the Z3 circuit.
block. This circuit breaker is HOT at all times. Cir For HORIZONTAL REARWARD function the cir
cuit A7 is the power supply for the circuit breaker. cuits are reversed. P17 is the feed, and P15 is the
The A7 circuit originates in the Power Distribution ground.
Center (PDC) and is protected by a 50 amp fuse When the operator selects the REAR VERTICAL
located in cavity 1. UP function, power is passed on the F37 circuit
Circuit F37 is the feed for the switches and the through the CLOSED contacts in the switch to the
seat motors from the circuit breaker. A bus bar inter P l l circuit. The P l l circuit connects to the motor.
nal to the switches feeds all the contacts. Grounding Ground is provided on the P13 circuit back to the
for the seats is provided on circuit Z3. switch. A ground bus bar internal to the switch then
connects to the Z3 circuit.
POWER SEAT For VERTICAL DOWN function the circuits are
When the operator selects the FRONT VERTICAL reversed. P13 is the feed, and P l l is the ground.
UP function, power is passed on the F37 circuit
through the CLOSED contacts in the switch to the
P19 circuit. The P19 circuit connects to the motor.
Ground is provided on the P21 circuit back to the
switch. A ground bus bar internal to the switch then
connects i t to ground on the Z3 circuit. The following index covers all components found in
For FRONT VERTICAL DOWN function the cir this section of the wiring diagrams. I f the component
cuits are reversed. P21 is the feed, and P19 is the you are looking for is not found here, refer to section
ground. 8W-02 for a complete list of all components shown in
When the operator selects the HORIZONTAL FOR the wiring diagrams.
WARD function, power is passed on the F37 circuit
8W-§3 POWER SEAT
8W**§3-2°
i l A O R A i INDEX
Circuit Breaker 2 8W-63-3 Fuse 1 ( P D C ) . . . . .
Forward/Backward Seat Motor 8W-63-3 Power Seat Switch
Front Up/Down Seat Motor 8W-63-3 Rear/Vertical Seat Motor
8050cd58
BR< 8W-63 POWER SEAT 8W - 63 - 3
BATTERY POWER
POSITIVE
TERNINAL
(8W-20-3.4)
AO
OERD A' 0
RIGHT I 20BK*
BATTERY
POSITIVE
TERNINAL
(WITH DIESEL
ENG)
(8W-20-4)
* WITH GAS ENG

** WITH DIESEL ENG
8050cd59 J968W-9
BR 8W - 70 SPLICE INFORMATION 8W - 70 - 1
8W-70 S P L I C E INFORMATION
DESCRIPTION AND OPERATION circuits that are part of the splices are shown, and
the systems they affect are referenced. For viewing
INTRODUCTION the location of each splice in the vehicle, refer to Sec
This section identifies all splices in the wiring dia tion 8W-95.
grams. It also shows the splices in their entirety. All
8W - 70 - 2 ~ —
8W-70 SPLICE INFORMATION
BR
DIAGRAM INDEX
Component
Page Component
Page
t]?! 8W-70-3 S156
0
I] *- 8W-70-3 8W-70-24
l] U6
8W-70-3 S157 8W-70-25
S °J 8W-70-3 S158 8W-70-25
t\Z 8W-70-4 S159 8W-70-26
S1
Z\™ 8W-70-4 60 8W-70-26

8W-70-4 S201 8W-70-26
5202 8W-70-27
till 8W-70-5 5203
5204
8W-70-27
8W-70-28
r]J: 8W-70-6
8W-70-6 5205 8W-70-28
8W-70-7 5206 8W-70-29
S113...' 5207 8W-70-29
S114 8W-70-7
5208 8W-70-30
S 1 1 c 8W-70-7 5209 8W-70-30
8 W 7 0 8
;;;;;;;; - - S210 8W-70-31
S117 8W-70-8
S212 8W-70-31
8W-70-9
S213 8W-70-32
5118 8W-70-9
S214 8W-70-32
5119 8W-70-9
S215 8W-70-33
5120 8W-70-10
5216 8W-70-33
5121 8W-70-10
5217 8W-70-34
5122 8W-70-11
5218 8W-70-34
S123... 8W-70-11
S301 8W-70-34
S124 8W-70-12
5302 8W-70-34
5129 8W-70-12
5303 8W-70-35
5130 8W-70-12
5304 8W-70-35
S131 8W-70-13
5305 8W-70-35
5132 8W-70-13
5306 8W-70-36
5133 8W-70-14
5307 8W-70-36
5134 8W-70-14
5308 8W-70-36
5135 8W-70-15
5309 8W-70-37
S136 8W-70-16
S310 8W-70-37
5137 8W-70-17
S311 8W-70-37
5138 8W-70-17
S312 8W-70-38
S139 8W-70-18
S313 8W-70-38
S140 8W-70-18
S314 8W-70-39
S141 8W-70-19
S315 8W-70-39
5142 8W-70-19
S316 8W-70-39
5143 8W-70-19
S317 8W-70-40
5144 8W-70-20
5318 8W-70-40
5145 8W-70-20
5319 8W-70-40
5146 8W-70-20
S320 8W-70-41
5147 8W-70-21
S401 8W-70-41
5148 8W-70-21
5402 8W-70-41
5149 8W-70-21
5403 8W-70-41
5150 8W-70-22
5404 8W-70-41
5151 8W-70-22
5405 8W-70-42
5152 8W-70-22
5406 8W-70-42
5153 8W-70-23
5407 8W-70-42
5154 8W-70-23
5408 8W-70-42
5155 8W-70-24
5409 8W-70-43
8050cd5c
J968W-9
BR 8W-70 SPLICE INFORMATION 8W - 70 - 3
S P L I C E S101 RIGHT PARK/

T U R N G N A L
S106 * L7 20BK/YL • L7 18BK/YL ^ J
< 8 W
- °- 7 4 )
(M^T-S,
RIGHT PARK/ C133 TURN SIGNAL/

S102
TURN SIGNAL HAZARD
LAMP •L60 18LG/TN- I L60 20TN/BK » L60 18TN/BK SWITCH
(8W-52-6) (8W-52-5)
(8W-50-5) (8W-50-5)
GROUND
JOINT
INSTRUNENT
LEFT PARK/ (3) C123

TURN SIGNAL
LANP •Zl 18BK-
(8W-52-6)
(8W-50-5)
4WD Zl
18BK
SWITCH RIGHT PARK/
(8W-31-8) C106
S103 TURN SIGNAL
(8W-34-6) •Zl 18BK <4— Z l 20BK- •Zl 18BK- LANP
(8W-35-7) (8W-52-6)
(8W-40-9) (8W-50-5)
WINDSHIELD
Z l 20BK- WASHER
SPLICE PUNP NOTOR
S409* •Zl 20BK < ( — - Z l 20BK (8W-53-4)
(8W-70-43)
FOG LANP
RIGHT
•Zl 20BK Z l 18BK- , RELAY NO. 1
HEADLANP
(8W-50-8)
(8W-50-5)
(8W-11-13,14)
C105 RIGHT
FOG LANP
RELAY NO. 2 •L39 20LB » L39 20LB- FOG LANP
(8W-50-9) C8W-50-10)
(8W-11-12)
C105 LEFT
S104*
-L39 20LB- -L39 20LB » L39 20LB- FOG LANP
(8W-50-10)
C133
•L39 18LB- •L39 20LB-
FOG LANP
SWITCH
(8W-50-10)
* WITH FOG LAMPS
8050ed5d J968W-9
8W-70-4* 8W-70 SPLICE INFORMATION BR
4WD
SWITCH
(SW-31-8) CONTROLLER
(8W-35-7)
(8W-40-9) G107 20BK/GY
6107
18BK
GY INSTRUMENT
C106
G107 20BK/GY
JOINT
LEFT PARK/ C133 C217 PARK
TURN SIGNAL LAMP CONNECTOR
L7 18BK/YL- L7 1 8 B K / Y L » — L7 1 8 B K / Y L —
LAMP SWITCH
(4) OUTPUT
(8W-52-6)
C8W-50-5)
SPLICE Slit SPLICE

S314 L7 20BK/YL- S101
18BK/YL^18BK/YL
(8W-70-39) (8W-70-3)
FOG LAMP TRAILER

R E L A Y NO. 1 TOW R E L A Y
L7 2 0 B K / Y L - L7 20BK/YL-
(8W-50-8) (8W-54-3)
(8W-11-13) C8W-11-6)
DAYTIME
DIMMER RUNNING
C131
SWITCH
LAMP
-L4 16VT/WT" —<f 10 LOW
MODULE
BEAM
OUTPUT
LEFT S107 RIGHT

HEADLAMP -L4 16VT/WT- •L4 16VT/WT- HEADLAMP
(8W-50-5) C8W-50-5)
HEADLAMP C133
DIMMER L4 L4
SWITCH •16VT <t -16VT-
(8W-50-4) WT WT
* WITH ABS
8050cd5e J968W-9
1
BR 8W-7Q SPLICE INFORMATION 8W - 70 - 5
LOW ABS WARNING TRAILER

WASHER LANP RELAY TOW RELAY
FLUID SWITCH (8W-35-6) C8W-S4-3)
(8W-53-4) ' (8W-11-16) (8W-11-6)
WITH
WITH TRAILER
ABS TOW
Zl 18BK- Z l 20BK-
WITH SPEED
CONTROL,
HIGH-LINE
VEH1CLE CLUSTER
SPEED
CONTROL Z l 20BK Zl 18BK
SERVO
(8W-33-4)
Zl 18BK
GROUND JOINT WITH

DRL
Zl 12BK
G101
# |8W-15-3|
VACUUN
SENSOR G9 20GY/BK- WITH
C8W-34-4) DIESEL ENG
(8W-35-5)
. . JOINT
BRAKE P- S109 G9 C133 G9 C209. RED BRAKE COiiEOTOR
•22GY- WARNING
SWITCH
(8W-34-4)
G9 16GY/BK- •20GY-
BK -»- BK (26) j
LAMP
DRIVER
C8W-35-S)
BLACK CONTROLLER
C121 RED BRAKE ANTI-LOCK
WARNING
G9 20GY/BK- -<f|25 LAMP .. BRAKE
DRIVER (ABS)
WITH
ABS
* WITH MEDIUM-LINE AND HIGH-LINE CLUSTER
8050cd5f J968W-9
8W - 70 - 6 8W-70'SPLICE INFORMATION- BR
• HOT I i RUN «4
CONTROLLER
ANTI-LOCK
BRAKE
12
cm
"))r A20 18RD/DB A20 18RD/DB
WITH
D I E S E L ENG
17 A20 18RD/DB
SllO'
A20 18RD/DB
/ VACUUM SENSOR
(8W-35-5)
FUSED
IGNITION
SWITCH •
OUTPUT A20 18RD/DB
(RUN)
A B S PUMP
A20 18RD/DB A20 18RD/DB MOTOR R E L A Y
(8W-35-6)
C8W-11-10)
21 )> A20 18RD/DB A20

18RD
DB A B S WARNING
LAMP R E L A Y
(8W-35-6)
(8W-11-16)
BRAKE
SWITCH •V40 20WT/PK
SENSE
C12S
r i POWERTRAIN
C137
V40 ! BRAKE |
20WT—• ( f H C24 SWITCH [ MODULE
PK [ SENSE j
* WITH ABS
8050cd60 J968W-9
r CONTROLLER
ABS
C121
PUMP MOTOR\ ANTI-LOCK
•B120 14BR/WT—<f" 34 RELAY 1
BRAKE
OUTPUT
•B120 12BR/WT-
HYDRAULIC RWAL
$112* VALVE
CONTROL -B120 12BR/WT- •B120 12BR/WT-
UNIT (8W-35-10)
(8W-35-9) -B120 12BR/WT•
ABS PUMP
MOTOR RELAY
•B120 12BR/WT• (8W-35-6)
C8W-11-16)
C127 F U E L SHUT
- T 4 0 12BR- -T40 12BR- DOWN R E L A Y
C8W-30-47)
ENGINE C119 ENGINE

STARTER STARTER
•T40 12BR- —• — T 4 0 12BR-- » — - T 4 0 12BR-
MOTOR RELAY MOTOR
(8W-21-4) S i l l * * (8W-21-4)
(8W-11-17)
• HOT I N S T A R T / R U N ^
FUSE
BLOCK
1 10A
C126 SPLICE
(33): C241 F18 18LG/BK- F18 18LG/BK- S132
(8W-70-13)
F18
22LG
BK
C133 FUEL PUMP
•F18 20LG/BK F18 2 0 L G / B K - RELAY
(8W-30-20,41)
(8W-11-11)
A/C
AUTOMATIC COMPRESSOR
S H U T DOWN CLUTCH
•F18 20LG/BK F18 20LG/BK-
RELAY RELAY
C8W-30-12) C8W-42-8)
C8W-11-10) TRANSMISSION
(8W-11-8)
RELAY
-F18 20LG/BK-
C8W-31-4)
C8W-11-9) *WITH ABS
* * W I T H DIESEL ENG
8050cd61 J968W-9
8W - 70 - 8 8W-70 SPLICE INFORMATION
UNDERHOOD
LANP
(8W-44-8)
C183
) NO CONNECTION
WINDSHIELD
WIPER
MOTOR
(8W-53-4)
C128
WITH
TRAILER
TOW
FUEL
PUNP
NODULE
(8W-30-21,42) C127 SPLICE
-Zll 16BK/WT- -Zll 16BK/WT- S140
C8W-70-18)
Zll
20BK
WT
C128 S116 C133 SPLICE
—« Z l l 20BK/WT- -Zll 18BK/WT- -Zll 18BK/WT- S208
C8W-70-30)
8050cd62 J968W-9
mm 8W-70 SPLICE INFORMATION 8W - 70 - 9
C208 DAY/NIGHT
L l 22VT/BK —-Ll 22VT/BK • NIRROR
(8W-44-9)
>|< C 1 3 3
BACK-UP Ll
LANP Ll 18VT
SWITCH -18VT- BK
BK
(8W-51-6)
Ll
18VT-
C126
-»
Ll I $117*
C129
1 8 V T - # — L l 18VT/BK - - » L l 18VT/BK •
SPLICE
S313
PARK/ BK BK (8W-70-38)
NEUTRAL Ll
POSITION -18VT-
SWITCH BK
(8W-51-6)
WITH
AUTO
TRANS
POWER
SPLICE
S203
(8W-70-27)
C133
-A3 12RD/LG- •A3 12RD/LG A3 12RD/LG•
POWER
TRAILER DISTRIBUTION
TRAILER TOW R E L A Y CENTER
TOW (8W-54-3)
(8W-54-4) (8W-11-6)
A6 A6
12RD 12RD
TN TN
A C332
C129 1
Mil
•A6 12RD/TN• — « A6 12RD/TN• •A6 12RD/TN•
• WITH TRAILER TOW

*WITH HIGH-LINE CLUSTER
**WITH DRL
8050cd63 J968W-9
8W-70-10 8W-70 SPLICE INFORMATION BR
JOINT DAYTIME
CONNECTOR FUSED
FUSED IGNITION RUNNING
IGNITION C SWITCH LAMP
SWITCH OUTPUT MODULE
OUTPUT (RUN)
(RUN) 5
(29) C209 C131
PARK/
LIO LIO LIO NEUTRAL
22BR 18BR -18BR- POSITION
LG LG LG SWITCH
LIO (8W-51-6)
CI33
-LIO 20BR/LG-
$120* LIO ^
18BR—
r
1
18BR—•
LG
C126 LIO
1 R
BACK-UP
yujp
LG " ?? I^
b
SWITCH
T (8W-51-6)
WITH
MAN
TRANS
INSTRUMENT
CLUSTER
HIGH
G34 C133 G34 C216 BEAM
-18RD- -18RD- INDICATOR
GY GY (13) LAMP
DRIVER
WITHOUT
DRL -
FOG LAMP S121 C133 HEADLAMP
RELAY NO. 1 •L3 16RD/0R- •L3 16RD/0R- DIMMER
•L3 16RD/0R-
(8W-50-8) SWITCH
(8W-11-14)- (8W-50-4)
LEFT RIGHT
HEADLAMP L3 16RD/0R- L3 16RD/0R- HEADLAMP
(8W-50-5) (8W-50-S)
WITH DRL
DAYTIME
DIMMER RUNNING
C131 SWITCH
•L3 16RD/0R- 1 HIGH LAMP
BEAM MODULE
OUTPUT
* WITH DRL
8050cd64 J968W-9
BR 8W-70 SPLICE INFORMATION 8W - 7 0 - 1 1
S212*
. RWAL
WALWE C133 8W-70-31
(8W-34-7) 12 18BK/LG•
WITH
ABS
WITH
ABS RWAL 12
2-WAY 18BK
WITH LG
RWAL POWER FEED
(8W-35-9) 12
18BK
C133 LG
Z2
18BK
WITH LG
•Z8 10BK/PK STANDARD WITH
SPEAKERS STANDARD
WITH WITH SPEAKERS
ABS ABS
RADIO
(8W-47-5,7,8,9)
CONTROLLER
ANTI-LOCK INSTRUMENT
BRAKE CLUSTER
CAWITY 2 0
(8W-35-4) LEFT 1 C 2 1 6
TURN '
SIGNAL (12)
L61
20LG
YL
TURN
LEFT PARK/ S123 C133 SIGNAL/
TURN SIGNAL •L61 20LG/YL ) > — L 6 1 18LG/YL
-L61 18LG/TN- HAZARD
LAMP SWITCH
(8W-52-6) (8W-52-5)
(8W-50-5) (8W-50-5)
* WITH PREMIUM SPEAKERS

** WITH MEDIUM-LINE AND HIGH-LINE CLUSTER
8050cd65 J968W-9
8W-70 SPLICE INFORMATION BR
POWER
FUSE POWER
OUTLET
BLOCK
C8W-41-3)
F130
(45): C241 18RD
YL
C133
$124
• A l 12RD- • A l 12RD- •Al 12RD— 1
ENGINE
CRANKSHAFT
$129* COOLANT
POSITION
•K4 20BK/LB K4 1 8 B K / L B - TEMPERATURE
SENSOR
SENSOR
C8W-30-27)
WITH (8W-30-26)
8 . 0 L ENG
INTAKE AIR
TEMPERATURE
K4 1 8 B K / L B •
SENSOR
(8W-30-23)
WITH
3.9L, 5 . 2 L AND 5 . 9 L
ENG
POWERTRAIN
CONTROL MODULE
SPLICE
C13S S154
SENSOR
A4^)>- •K4 20BK/LB (8W-70-23)
GROUND
C136
5 VOLT
B31t-»- •K7 1 8 0 R -
SUPPLY
i—.
TRANSMISSION
SOLENOID ASSEMBLY
VEHICLE
5 VOLT $130** SPEED
K7 1 8 0 R - •K7 1 8 0 R -
SUPPLY SENSOR
(8W-30-14)
* WITH GAS ENG

** WITH AUTO TRANS
8050cd66 J968W-9
BR 8W-70 SPLICE INFORMATION 8W - 70 - 1 3
C127 C133 SPLICE

- » - G 7 22WT/OR—»—G7 20WT/0R— $210
(8W-70-31)
G7
20WT
OR
POWERTRAIN
CONTROL NODULE
VEHICLE C136 VEHICLE
SPEED S131 . SPEED
SENSOR B27 -G7 20WT/OR- -G7 18WT/0R-
SENSOR
SIGNAL (8W-30-14)
FUSED C135
IGNITION
SWITCH A2
OUTPUT
(START/RUN)
F18**
18LG
BK
SPLICE FUEL
S114 •F18 18LG/BK F18 20LG/BK- SHUT DOWN
(8W-70-7) SOLENOID
WITH C8ltf-30-47)
DIESEL
ENG
DUTY CYCLE HEATED

EVAP/ INTAKE
PURGE •F18 20LG/BK F18 20LG/BK- AIR SYSTEM
SOLENOID RELAY NO. 1
(8W-30-20) (8W-30-48)
EXHAUST GAS HEATED

RECIRCULATION INTAKE
SOLENOID -F18 20LG/BK F18 20LG/BK- AIR SYSTEM
(8W-30-20) RELAY NO. 2
(8W-30-48)
WITH
5.2L AND WITH
5.9L ENG DIESEL
ENG
FU~L
HEATER
RELAY
(8W-30-47)
* WITH GAS ENG

** WITH DIESEL ENG
8050cd67 J968W-9
8W-70-14 8W-78 SPLICE I N F O i i A I i O l
INJECTOR INJECTOR
NO. 1 NO. 3
C8W 3 0 - 3 0 , 3 4 , 3 9 ) (8W-30-30,34,39)
WITH
3.9L. 5.2L
AND 5 . 9 L
ENG
UPSTREAM
HEATED
OXYGEN -A142 16DG/0R
SENSOR
(BW-30-29,32,333
DOWNSTREAM
HEATED INJECTOR
OXYGEN ^ • A142 16DG/0R NO. S
SENSOR (8W-30-30,34,39)
(8W-30-29,32,33)
WITH
3.9L. 5.2L
AND 5 . 9 L
ENG
LEFT RIGHT
UPSTREAM UPSTREAM
HEATED HEATED
• A142 16DG/0R
OXYGEN OXYGEN
SENSOR SENSOR
C8W-30-37) WITH C8W-30-37)
8 . 0 L ENG
SPLICE WITH
$138 • A142 14DG/0R 5.2L, 5.9L
C8W-70-17) AND 8 . 0 L
ENG
INJECTOR INJECTOR
NO. 9 • NO. 7
C8W-30-39) (8W-30-34,39)
POWERTRAIN
C O N T R O L MODULE
C136 $134
GENERATOR
FIELD BlOl -K20 18DG- •K20 18DG-
GENERATOR
DRIVER (8W-20-3,4>
* WITH GAS ENG
8050cd68 J968W-9
8W-70 SPLICE INFORMATION 8W-70 15
INJECTOR INJECTOR
NO . 2 NO. 6
(8W-30-31,35,40) (8W-30-31,35.40)
INJECTOR . INJECTOR
NO. 4 NO. 8
(8W-30-31,35,40) C8W-30-35.40)
A142
16DG
OR
WITH
5.2L.5.9L
AND 8 . 0 L
ENG
IGNITION
COIL
A142 14DG/0R
4-PACK.
CSif-3§~3.§)
WITH
IGNITION 8 . 0 L ENG
COIL
• A142 14DG/0R
6-PACK
(8W-30-36)
WITH
3.9L, 5 . 2 L
AND 5 . 9 L
ENG
A142 A142 A142

14DB 14DG 14DG
I OR OR
GENERATOR SPLICE IGNITION

(8W-20-3) S138 COIL
C8W-30-28) (8W-70-17) (8W-30-28)
* WITH GAS ENG
8050cd69 J968W-9
8W-70-16 8W-70 SPLICE INFORMATION^
INTAKE
Alt CAMSHAFT
TEMPERATURE POSITION
SENSOR SENSOR
(8W-30-23) (8W-30-22)
WITH
8.0L
ENG
PRE-
CATALYST
HEATED
•K4 18BK/LB
OXYGEN
SENSOR
(8W-30-38)
POST
CATALYST
HEATED
•K4 18BK/LB
OXYGEN
SENSOR
(8W-30-38)
CRANKSHAFT
POSITION
K4 1 8 B K / L B -
SENSOR
(8W-30-27)
WITH
3.9L, 5.2L
AND 5 . 9 L
ENG
DOWNSTREAM
HEATED
OXYGEN •
SENSOR
(8W-30-29,32>
WITH
3.9L, 5.2L THROTTLE SPLICE MANIFOLD
AND 5 . 9 L POSITION S154 ABSOLUTE
ENG SENSOR (8W-70-23) PRESSURE
(EXCEPT (8W-30-24) (8W-30-23)
HEAVY DUTY)
* WITH GAS ENG
8050cd6a J968W-9
BR 8W-70 SPLICE INFORMATION 8W-7Q-17
THROTTLE
POSITION
SENSOR
(8W-30-24,44)
POWERTRAIN WITH
CONTROL MODULE GAS ENG
C13S CAMSHAFT
K6 K6 POSITION
-20VT- -20VT K6 20VT/WT-
SUPPLY SENSOR
WT WT
(8W-30-22)
EGR
CONTROL
WITH
K6 20VT/WT• MODULE
CRANKSHAFT DIESEL ENG
POSITION WITH MAN TRANS CAVITY 12
SENSOR WITHOUT EGR (8W-30-49)
WITH
(WITH GAS ENG) DIESEL ENG
(8W-30-27) K6 WITH EGR
OR -20VT- MANIFOLD
ENGINE WT ABSOLUTE
K6 20VT/WT•
SPEED PRESSURE
SENSOR (8W-30-23)
(WITH DIESEL ENG) WITH
(8W-30-46) GAS ENG
AUTOMATIC
S H U T DOWN
RELAY
(8W-30-12)
(8W-11-10)
I
SPLICE SPLICE
$133 • A142 14DG/0R A142 14DG/0R- . S135
<8W 7 0 - 1 4 ) C8W-70-15)
PRE-
CATALYST
HEATED
• A142 16DG/0R
OXYGEN
SENSOR
(8W-30-38) WITH
CAL TRANS
POST
CATALYST INJECTOR
HEATED A142 16DG/0R- - NO. 1 0
•A142 16DG/0R
OXYGEN C8W-30-40)
SENSOR
C8W-30-38) WITH
8 . 0 L ENG
C O N T R O L MODULE
* WITH GAS EN(
8050cd6b J968W-
8W - 7 0 - 1 8 8W-70 SPLICE INFORMATION BR
C135 POWERTRAIN
-Z12 14BK/TN- -<£-{ A31 GND CONTROL
SPLICE Z12 MODULE
S151 -10BK-
(SW-70-22) TN Z12
-10BK- S139
•SPLICE Zl? TN
S142 -10BK-
(8W-70-19) TN
•Z12 14BK/TN- -<£•* A32 GND !
WITH
DIESEL ENG
ENGINE
COOLANT
SENDING
UNIT
(8W-40-6)
BLACK
WITH
8.0L ENG
POST
CATALYST
HEATED SPLICE
18BK/WT SI16
OXYGEN
SENSOR (8W-70-8)
C8W-30-38)
PRE- A/C
CATALYST COMPRESSOR
HEATED CLUTCH
OXYGEN (8W-42-8)
SENSOR LEFT
(8W-30-38) UPSTREAM
HEATED
UPSTREAM OXYGEN
HEATED SENSOR
OXYGEN (8W-30-37)
SENSOR
(8W-30-29.32.33)
DOWNSTREAM
- HEATED
OXYGEN
SENSOR RIGHT
(8W-30-29.32.33)
UPSTREAM
HEATED
OXYGEN
SENSOR
(8W-30-37)
SPLICE
S150
(8W-70-22)
SPLICE
S142
(8W-70-19)
DATA LINK
WITH CONNECTOR
DIESEL ENG C8W-30-13)
* WITH GAS ENG
S050cd6c J968W-9
BR 8W-70 SPLICE INFORMATION 8W-70-19
SPLICE
ENGINE -Z12 20BK/TN- S151*
STARTER C12S (8W-70-22)
MOTOR -T41 22BK/WT » — OR
RELAY WITH SPLICE
(8W-21-3.4) MAN TRANS
S152**
(8W-11-17) (8W-70-22)
T41
20BK
PARK/ WT POWERTRAIN
NEUTRAL
POSITION - -T41 18BK/WT- -T41 20BK/WT
SWITCH $141 1
C8W-21-3.4)
SPLICE
$139 -Z12 10BK/TN-
(8W-70-18)
S142'
FUEL
•Z12 16BK/TN- i HEATER
(8W-30-47)
SPLICE
S1S2 -Z12 14BK/TN- Z12
14BK SPLICE
(8W-70-22)
TN - Z l l 16BK/WT- $140
(8W-70-18)
G119
8W-15-12
AUTOMATIC C127 POWERTRAIN

SHUT DOWN ^ • A142 14DG/0R-<f~ A142 14DG/0R — i A142 16DG/0R
RELAY
(8W-30-12)
(8W-11-10)
EXHAUST
GAS
RECIRCULATION •A142 18DG/0R
SOLENOID
(8W-30-49)
. GENERATOR
A142 14DB- (8W-20-4)
EGR (8W-30-45)
CONTROL •A142 20DG/0R
MODULE
CAVITY 1
(8W-30-49)
• WITH AUTO TRANS
* WITH GAS ENG
** WITH DIESEL ENG
8050cd6d J968W-9
8W - 70 - 20 8W-70 SPLICE INFORMATION BR
FUEL S144' FUEL

HEATER -A12 200R- HEATER
FEED - A 1 2 14RD/TN-
RELAY
C8W-30-47) (8W-30-473
FUEL FUEL
SHUT S145*
SHUT
DOWN -A18 16DB- - A 1 8 10RD/BK- DOWN
FEED RELAY
(8W-30-47) (8W-30-47)
POWER
DISTRIBUTION
TPKE CENTER
% 40A
(2) C180
S146 C133 IGNITION

•A2 12PK/BK- A2 12PK/BK — ) ) — A2 12PK/BK - - SWITCH
(8W-30-11)
A2
12PK
BK
ENGINE
STARTER
MOTOR
RELAY
(8W-21-3.4)
(8W-11-17)
* WITH DIESEL ENG

8050cd6e J968W-9
8W-70 SPLICE INFORMATION 8W - 70 - 21
FOG LAMP
RELAY NO. 2
S 1 5 5
(8M-50-9)
(8W-11-12) <8W-70-24)
L38
F31
20LB
18VT
BK
POWER
DISTRIBUTION
CENTER
WITH
POWER
SEAT S204
rA A7
12RD-
BK
8W-70-28
A7
•12RD-*
BK
A7
-12RD-
BK
A7
12RD
BK
ENGINE
STARTER
AO 6RD*— AO OOERD* M
NOTOR FUSE
(8W-21-3.4) BLOCK
1 ( 1 4 ) '* C241 !
POWER
DISTRIBUTION ! k FUSE k FUSE "s FUSE |
AO 6RD-
CENTER ! r 19 r 17 c; J
18 j
(8W-11-6 THRU 2 0 ) i 1 20A 1 15A <I 15A ]
S148
AO 20BK- -A15 16PK
BATTERY
POSITIVE
TERNINAL S148
(8W-20-3.4) s* AO 14PK- -A15 20BK
WITH
DIESEL ENG
RIGHT BATTERY
-AO OERD POSITIVE TERNINAL
(WITH DIESEL ENG)
(8W-20-4)
UNDERHOOD S149 C183

NO
LANP -Ml 20PK- -Ml 20PK-
CONNECTION
(8W-44-8)
C133
SPLICE
•Ml 20PK- -Ml 20PK- S205
(8W-70-28)
* WITH GAS ENG

** WITH DIESEL ENG
8050cd6f J968W-9
SPLICE
SPLICE S140
S141 (8W-70-18)
(8W-70-19)
T41 Zll
20BK 16BK
WT
WT S150* G119
•Z12 14BK/TN- 8W-15--11
Z12
C125 10BK
TN
C126
-Z12 20BK/TN- Mil* •Z12 20BK/TN - ) ) - -Z12 20BK/TN-
C133
WITH
T41 MAN TRANS Z12 Z12
22BK 10BK 20BK
WT TN TN
ENGINE SPLICE DATA LINIC

STARTER S139 CONNECTOR
MOTOR C8W-70-18) (8W-30-13)
RELAY
(8W-21-3)
C8W-11-17)
SPLICE
S141 C126
(8W-70-19)
-Z12 20BK/TN-
T41 Z12
20BK 20BK C133
WT TN
Z12
20BK
C125 TN
I
T41 S152**
22BK -Z12 20BK/TN- #c ^ Z12 14BK/TN-
DATA LINK
WT CONNECTOR
WITH (8W-30-13)
MAN TRANS Z12 Z12
ENGINE Z12
STARTER 18BK 18BK 20BK
MOTOR
TN TN TN SPLICE
RELAY WITH S142
(81-21-4) EGR (8W-70-19)
(8W-11-17)
EGR FUEL FUEL
CONTROL SHUT HEATER
MODULE DOWN RELAY
CAVITY 10 RELAY (8W-30-47)
(8W-30-49> (8W-30-47)
* WITH GAS ENG
** WITH DIESEL ENG
8050cd70 J968W-9
SPLICE
-G34 18RD/GY- S121
C133 (8W-70-10)
-G34 18RD/GY-
- « -
WITH
G34 DRL
18RD
GY G34
18RD
GY
(13) : C216
INSTRUMENT HIGH
DAYTIME
HIGH CLUSTER C131 BEAM RUNNING
BEAM
5153
-G34 1 8 R D / G Y — < f i 4 INDICATOR LAMP
INDICATOR MODULE
LAMP
LAMP
DRIVER
DRIVER
i
G34
18RD
GY
f
FOG LAMP
RELAY NO. 1
(8W-11-13.14)
(8W-50-8)
VEHICLE
SPEED
LEFT SENSOR
UPSTREAM (8W-30-14)
HEATED -K4 18BK/LB
OXYGEN
SENSOR
(8W-30-37)
RIGHT
UPSTREAM 1 TRANSMISSION
HEATED SOLENOID.
OXYGEN ASSEMBLY
SENSOR
(8W-30-37)
WITH
5 . 9 L ENG
WITH HEAVY
DUTY
UPSTREAM DOWNSTREAM
HEATED HEATED
OXYGEN OXYGEN
SENSOR SENSOR
(8W-30-29, SPLICE > SPLICE SPLICE (8W-30-33)
32.33) WITH S136 S156 - $129
3.9L.5.2L (8W-70-16) (8W-70-24) C8W-70-12)
* WITH DRL
AND 5 . 9 L
** WITH GAS ENG
ENG
8050cd71 J968W-9
SPLICE
A7 12RD/BK $147
(8W-70-21)
A/C
• F 3 1 20VT F31 20VT-
COMPRESSOR
HORN CLUTCH
RELAY RELAY
(8W-41-4) (8W-42-8)
C8W-11-7) -F31 20VT (8W-11-8)
BATTERY C133 VEHICLE

TEMPERATURE •K4 20BK/LB- K4 2 0 B K / L B » - K 4 18BK/LB - SPEED CONTROL/
SENSOR HORN SWITCH
<8W-30-24,45) (8W-33-3)
C125 • C128 FUEL

•K4 2 0 B K / L B • K4 2 0 B K / L B )] K4 2 0 B K / L B • PUMP
MODULE
K4 (8W-30-21,42)
20BK
LB
SPLICE
•K4 2 0 B K / L B • S154
(8W-70-23)
SPLICE
•K4 2 0 B K / L B S157
(8W-70-25)
WITH
DIESEL ENG
8050cd72 J968W-9
8W-70 SPLICE INFORMATION 8W - 70 - 2S
THROTTLE
POSITION
SENSOR
(8W-30-44) POWERTRAIN
CONTROL MODULE
INTAKE
AIR C135
SENSOR
TEMPERATURE -K4 16BK/LB K4 2 0 B K / L B •
GROUND
SENSOR
(8W-30-44)
WATER
-III- $117* C125 SPLICE
FUEL i -K4 20BK/LB K4 2 0 B K / L B — — K4 2 0 B K / L B • S156
SENSOR C8W-70-24)
C8W-30-44)
TRANSMISSION
SOLENOID ASSEMBLY
ENGINE £167
SPEED •K4 20BK/LB K4 1 8 B K / L B •
SENSOR
SENSOR — < f GROUND
(8W-30-46)
VEHICLE
SPEED
SENSOR
(8W-30-14)
INSTRUMENT
CLUSTER
ABS
WARNING $158* C133 C215 ABS
LAMP -G19 20LG/RD-
WARNING
RELAY | G19 2 0 L G / R D — ) ) — G 1 9 22LG/RD——<f LAMP
(14) DRIVER
(8W-35-6)
(8W-11-16)
G19
20LG
RD
CONTROLLER
ANTI-LOCK
BRAKE
CAVITY 24
(8W-35-6)
(8W-11-16)
* WITH DIESEL ENG

* * WITH ABS
8050cd73 J968W-9
8 W . 7 0 . 26 — • — 8W-70-SPLICE I N F O R M A T I O N - — — — BR
Ell
CONTROL
MODULE
CAVITY 3
(3W-30-49)
K22
200R
DB
• POWERTRAIN
CONTROL MODULE
THROTTLE C135 THROTTLE
POSITION -K22 200R/DB-
Mit* POSITION
-K22 200R/DB- A23
SENSOR SENSOR
(8W-30-44) SIGNAL
POWERTRAIN
CONTROL MODULE
C125 S160 C137 A/C
-C90 18LG-
PRESSURE
-C90 18LG- — < f C23
SWITCH
C90 OUTPUT
18LG
C90
^ C133 18LG
C90
22LG
A/C HIGH
A/C-HEATER PRESSURE
CONTROL CUTOUT
SWITCH SWITCH
(8W-42-6) (8W-42-6)
(8W-30-15)
FUSE
C241 F2 BLOCK
J
A22 12BK/0R ({ •—- ^\y-
(11) 30A
IIGNITION
! SWITCH
! C212 CB1
ACC / START;
* I p -A22 12BK/0R- A22 12BK/0R J(f-
J
! (5) (7) 30A
OFF RUN
FUSE 1 4
——^
20A
A22 12BK/0R (f-
(23) FUSE 1 5
— r \ j # .
10A
FUSE 1 6
— r
\ j O-
15A
* WITH DIESEL ENG

8050cd74 J968W-9
INTERMITTENT
• HOT I N ACC/RUN <4
WIPER
CONTROL FUSE
•V6 18DB/BK• BLOCK.
MODULE
CAVITY 3
FUSE
(8W-53-3,4) 8
20A
(44); C241
INTERMITTENT
WIPER S202
•V6 16DB/BK- •V6 16DB/BK•
SWITCi
(8W-53-3)
V6
18DB
BK
WINDSHIELD C133
WIPER
•V6 18DB/BK•
MOTOR
(8W-53-4)
C133 S203
•A3 12RD/LG• -A3 12RD/LG
A3
12RD
LG
HEADLAMP
•A3 12RD/LG- SWITCH
(8W-50-4)
t t
A3 A3
12RD 12RD
LG LG
S118 A3 12RD/LG
8W-70-9
-A3 12RD/LG-
WITH
DRL
8050cd75 J968W-9
8W - 70 - 28 8W-70 SPLICE INFORMATION mm
S204* C133
A7 12RD/BK-
A7
12RD
BK
SPLICE
S147
(SW-70-21)
JOINT
SPLICE
CONNECTOR B S149
r
C231 (8W-70-21) C208
SPLICE
FUSED
{{ Ml 20PK- - S320**
B(+)
(8W-70-41)
SPLICE
Ml 1 8 P K — - ) ) - M l 1 8 P K - S303
(8W-70-35)
TIME
• DELAY
Ml 20PK-
RELAY
(8W-44-4.5)
• HOT AT ALL T I M E S «4
POWER M I R R O R
SWITCH * WITH POWER SEAT
C8W-62-3) ** WITH CONSOLE
8050cd76 J968W-9
BR 8W-70 SPLICE INFORMATION :
8W - 7 0 - 2 9
FOG LAMP 1 INTERMITTENT

SWITCH WIPER CONTROL i INSTRUMENT
(8W-50-10) MODULE GND
CLUSTER
(10): C216
WITH
FOG
LAMPS Z3 20BK/0R-
KEY-IN-SWITCH/
Z3 20BK/0R- HALO LAMP
(8W-44-5)
Z3 20BK/0R-
C218
BUZZER
GND MODULE
HEADLAMP
SWITCH
(8W-44-5)
(8W-49-4) C228 CONTROLLER
Z3 16BK/0R- i 1 0 GND ANTI-LOCK
J BRAKE
SPLICE
S215 WITH
(8W-70-33) RWAL
CENTER HIGH
L50 18WT/TN- MOUNTED STOP
LAMP NO. 1
(8W-51-9)
CENTER HIGH
L50 L50 18WT/TN- MOUNTED STOP
18WT LAMP NO. 2
TN (8W-51-9)
C202 S207 TURN SIGNAL/

•L50 18WT/TN L50 18WT/TN- -HAZARD SWITCH
(8W-52-5)
C133
-L50 18WT/TN
L50
18WT
TN
si c m STOP LAMP
NO SWITCH
CONNECTION (8W-51-8)
(8W-52-4)
8050cd77 J968W-9
8W-70-30 8W-7I SPLICE INFORMATION BR
" OVERHEAD
GND ! CONSOLE
(9): C338
SPLICE
S2IS
(8W-70-33)
Zll
INSTRUMENT 20BK
GND GND CLUSTER WT
(9) C21S (6)^Q C216
C208
Z3 Zll Zll
12BK 20BK 20BK -Zll 20BK/WT-
OR WT WT
WITH
OVERHEAD
CONSOLE
S208
-Zll 18BK/WT-
C133
STOP
LAMP M
-Zll 20BK/WT- Zll Zll
SWITCH
18BK 18BK
(8W-33-4)
WT WT
(8W-34-5)
(8W-35-7)
SPLICE
0202 S116
8W-15-13 (8W-70-8)
INSTRUMENT
FUSED CLUSTER
IGNITION
SWITCH
OUTPUT
(START/RUN)
• HOT IN START/RUN <4
(8): C215 FUSE
BLOCK
AIRBAG
F14
CONTROL 20LG
MODULE YL
FUSED C232
IGNITION S209
SWITCH IJ -F14 1 8 L G / Y L - -F14 18LG/YL
OUTPUT
(START/RUN)
F14
20 LG
YL
MESSAGE
CENTER
CWf 4 6 - 3 )
8050cd78 J968W-9
C133 C127
SPLICE
—{{ 67 22WT/0R- - { { 67 2 0 W T / 0 R — m S131
(8W-70-13)
IMSTRUMENT
67
CLUSTER 20WT
OR
VEHICLE C216
SPEED S210
•G7 20WT/OR-
SENSOR
SIGNAL (11)

PREMIUM PREMIUM
•Z2 1 8 B K / L G -
SPEAKER SPEAKER
C8M-47-8) (8W-47-9)
OPTIONAL
Z2
Z2 C345 18BK
18BK Z2 1 8 B K / L 6 — < ( — Z 2 18BK/L6 LG
Z2
LG
j
18BK €347
LG -Z2 1 8 B K / L G •
Z2
18BK
LG €133 SIM**
OPTIONAL Z2 1 8 B K / L G - <f-Z2 18BK/L6-# |8W-70-ll
Z2
18BK
LG
C201
-Z2 18BK/LG
RADIO
CHOKE •Z2 18BK/LG Z2 1 8 B K / L G ,
(8W-47-7)
-Z2 18BK/L6
Z2 1 8 B K / L G •
t
Z2
C202
WITH
STANDARD
18BK
SPEAKERS
LG
WITH
RADIO LOW-LINE WITH
CLUSTER RWAL
SPLICE <8W-47-5,7,8.9)
S301 I Z8 10BK/PK
(6N-70-S4)
ABS WITH
2-MAY ABS
POWER FEED * WITH PREMIUM SPEAKERS
C8W-35-9) ** WITH MEDIUM-LINE AND H I G H - L I N E C L U S T E R
8050cd79 J968W-9
8W-70-32 8W-7I I P O CE .INFORMATION BR
C201
-X13 18BK/RD X13 18BK/RD-
I w
OPTIONAL OPTIONAL
X13 X13
18BK 18BK
RD RD
X13 X13
18BK
€347 C34i 18BK
-
RD R D
X13 X13
18BK 18BK
RD RD

PREMIUM SPEAKER PREMIUM SPEAKER
(8W-47-8) C202 (8W-47-9)
RADIO
CHOKE
RELAY
(8W-47-7)
SPLICE
S302
(8W-70-34)
C207
•F21 14TN- F21 14TN•
F21
OPTIONAL OPTIONAL
-4 F21
14TN 14TN
F21 F21
14TN
C347 C345 14TN
F21 F21
14TN 14TN
L E F T POWER RIGHT POWER

WINDOW SWITCH WINDOW SWITCH
C8W-60-3) (8W-60-4)
• HOT I N RUN <
8050cd7a J968W-9
8W-70 SPLICE INFORMATION SW - 70 - 33
POWER SPLICE CIGAR

OUTLET S206 LIGHTER
C8W-41-3) C8W-70-29) (8W-41-3)
BLACK
FOG
^ , G L O V E BOX
LAtflP
•Z3 20BK/0R Z3 16BK/0R—L LAMP/SWITCH
SWITCH * — x 1
(8W-44-8)
(8W-50-10)
HEATER
CONTROL
SWITCH
C8W-42-4)
SPLICE Z3 12BK/0R- —i OR
S208 •Zll 18BK/WT A/C-HEATER
(8W-70-30) CONTROL
SWITCH
(8W-42-6)
OVERDRIVE
SWITCH
Z3 20BK/0R- ILLUMINATION
LAMP
C8W-31-7)
L E F T POWER R I G H T POWER
DOOR DOOR
LOCK S W I T C H LOCK. S W I T C H
(8W-61-3) (8W-61-4)
F35 • HOT A T ALL T I M E S <4 F35

14RD 16RD
FUSE
BLOCK
i * 4
OPTIONAL OPTIONAL
F35 F35
14 RD 16RD
F35 F35
C348 C346
14RD 16RD
F35 F35 F35

14RD 16RD 16RD
F35 F35
14RD 16RD
C207 C239
S216
-F35 16RD- F35 16RD—-((-
8050cd7b J968W-9
8W - 71 - 34 8W~7i SPLICE INFORMATION mm
BLOWER MOTOR
-C7 12BK/TN- C8W-42-4,5)
HEATER
CONTROL
BLOWER SWITCH
MOTOR C237 $217 (8W-42-4)
RESISTOR C7 1 2 B K / T N — ( ( C7 1 2 B K / T N - -C7 1 2 B K / T N - OR
BLOCK A/C-HEATER
(8W-42~4 5) P CONTROL
SWITCH
(8W-42-6)
C202
-M2 2 0 Y L - DOME LAMP
(8W-44-5)
M2
20YL
C183 C133 C217 JOINT

S218 COURTESY
CONNECTOR
NO CONNECTION ( -M2 18YL )>— -M2 20YL- •M2 20YL (f- LAMPS
DRIVER
(6)
LEFT REAR
-Z2 18 B K / L G - PREMIUM
SPEAKER
(8W-47-7)
SPLICE C202 S301' RIGHT REAR

S212 Z2 18BK/LG )) Z2 18BK/LG 1 -Z2 18BK/LG-
PREMIUM
(8W-70-31) SPEAKER
CSW-47-7)
LEFT REAR
X13 18BK/RD- PREMIUM
SPEAKER
(8W-47-7)
SPLICE C202 RIGHT REAR

S302' PREMIUM
S213 •X13 18BK/RD- X13 18BK/RD- •X13 18BK/RD-
C8W-70-32) SPEAKER
(8W-47-7)
8050cd7c J968W-9
8W-70-SPLICE INFORMATION 8W - 71 - 3S
C202
SPLICE CARGO LAMP
S205 • M l 18PK- - M l 18PK- •Ml 18PK- NO. 1
(8W-70-28) (8W-44-5)
WITH
- CARGO
$303 €308 LAMPS
CARGO LAMP
DOME LAMP - M l 18PK- - M l 18PK- Ml 18PK- NO. 2
(8W-44-5)
8W-44-5)
RADIO
C201 C230
j X53 18DG )> X53 20DG -<£ L E F T DOOR
-X53 18DG- TWEETER
(4)
(8W-47-8)
-X53 18DG- L E F T DOOR

S304*
PREMIUM
X53 18DG- -X53 1 8 D 6 -
C347 SPEAKER
(8W-47-8)
X53 18DG-y<f~X53 18DG —•
OPTIONAL
RADIO
C201 C229 j LEFT i
X55 X55
-18BR- -20BR // i FRONT ! L E F T DOOR
\\ TWEETER
RD RD ] DOOR i •X55 18BR/RD-
(2) « SPEAKER! C8W-47-8)
j (-) i
X55 18BR/RD- L E F T DOOR

X55 S305* PREMIUM
-18BR- •X55 18BR/RD-
€347 RD
SPEAKER
X55 X55 (8W-47-8)
-18BR- -18BR-
RD RD
OPTIONAL
8050cd7d J968W-9
8 W - 7 0 - 36 8W-70 SPLICE INFORMATION
L E F T POWER
LEFT POWER WINDOW SWITCH
DOOR LOCK. C8W-60-3)
SWITCH
C315
Z3
GND I—»— Z3 14BK/0R- 14BK
OR
1(2)! I S306"
POWER
NIRROR
I SWITCH
•13 18BK/0R-
Z3 (8W-62-3)
GND | — » * — Z3 14BK/0R-
14BK
!(4) OR WITH
POWER
MIRRORS L E F T DOOR
JANB
SWITCH
(8W-49-4)
OPTIONAL
Z3 WITHOUT
14BK OPTIONAL
OR
Z3 I H OPTIONAL
^ C347 14BK
OR Z3 Z3
Z3 20BK 18BK
14BK OR OR
OR
1,
G302
•Z3 14BK/0R- 8W-15-14
RADIO
RIGHT
C240 C230 FRONT
-X54 18VT- -X54 20VT- DOOR
(5) SPEAKER
(+) RIGHT DOOR
TWEETER
(8W-47-9)
X54
18VT
-X54 18VT-
RIGHT DOOR
S307* PRENIUN
-X54 18VT- -X54 18VT-
C345 SPEAKERS
-X54 1 8 y T - j < f - X 5 4 18VT •
(8W-47-9)
t
OPTIONAL RADIO
C240 C229
-X56 1 8 D B / R D — — » X56 20DB/RD—-<(-
(3)
RIGHT DOOR
TWEETER
X56 (8W-47-9)
18DB
-X56 18DB/RD- RD
RIGHT DOOR
S308* PRENIUN
-X56 18DB/RD- -X56 18DB/RD-
C345 SPEAKERS
-a-X56 1 8 D B / R D - < f X56 18DB/RD- (8W-47-9)
t
OPTIONAL * WITH POWER WINDOWS AND POWER LOCKS
* * WITH PREMIUM SPEAKERS
8050cd7e J968W-9
BR- 8W-70 SPLICE INFORMATION 8W - 70 - 37
P33 P33
160R 160R
BK BK
LEFT POWER
P33 P33 DOOR LOCK.
160R C239 160R MOTOR
BK BK (8W-61-5)
OPTIONAL P33 P33 P33 C348
160R 160R 160R
C346 BK BK BK OPTIONAL
i
P33 P33
160R C207 160R
BK BK
P33
160R
BK
P33
160R
BK
RIGHT POWER RIGHT POWER

DOOR LOCK S309 DOOR LOCK
•P33 160R/BK •P33 160R/BK-
SWITCH MOTOR
(8W-61-4) (SW-61-5)
P34 P34
16PK 16PK
BK BK
LEFT POWER
P34 P34 DOOR LOCK
16PK C239 16PK MOTOR
BK BK (8W-61-5)
OPTIONAL P34 P34 P34 C348
16PK 16PK 16PK
C346 BK BK BK OPTIONAL
P34 P34
16PK
BK i C207 16PK
BK
P34
16PK
BK
P34
16PK
BK
RIGHT POWER RIGHT POWER

DOOR LOCK $310 DOOR LOCK
-P34 16PK/BK- •P34 16PK/BK-
SWITCH MOTOR
(8W-61-4) (8W-61-5)
FUEL PUMP
MODULE
(8W-30-21,42)
C128 Z13
16BK
-Z13 1 6 B K - » - Z 1 3 1 2 B K - -Z13 16BK-
SPLICE $311 SPLICE
S115 C128 $312
(8W-70-8) C8W-70-38)
•Z13 1 2 B K - » - Z 1 3 1 6 B K - -Z13 12BK-
WITH WITH
TRAILER TOW TRAILER TOW
8050cd7f J968W-9
8W - 70 - 38 8W-70 SPLICE INFORMATION -
C329 SPLICE
Z13 18BK » Z13 18BK- S402
TRAILER (8W-70-41)
TOW WITH DUAL
C8W-54-4) REAR WHEELS
WITH SPLICE
TRAILER TOW -Z13 1 8 B K - S405
Z13 C8W-70-42)
12BK C332
-Z13 12BK Z13 1 8 B K - ) > - Z 1 3 1 8 B K -
LEFT
-Z13 1 8 B K - ( LICENSE
RIGHT LANP
LICENSE C8W-51-4)
LANP
<8lf-51-4,10) C333
SPLICE
I Z13 18BK- -Z13 1 8 B K - S401
(8W-70-41)
Z13
18BK C342
-Z13 18BK Z13 1 6 B K -
SPLICE
S311
C8W-70-37)
Z13 1 2 B K -
WITH
WITH TRAILER
HIGH-LINE TOW
CLUSTER
$117 BACK-UP
8W-70-9 LANP
Ll Ll 18VT/BK-
SWITCH
-18VT-
BK C126 (8W-51-6)
Ll Ll
-18VT- -18VT-
BK BK PARK
NEUTRAL
r
Ll Ll
•Ll 18VT/BK POSITION
18VT 18VT SWITCH
BK BK C8W-51-6)
WITH
AUTO TRANS
C129
Ll 18VT/BK-
TRAILER Ll
TOW 18VT
(8W-S4-4) WITH
TRAILER TOW BK
C331 1 $313
C329 RIGHT
BACK-UP
Ll 16VT/BK• Ll 18VT/BK" Ll 18VT/BK — ) ) — L l 18VT/BK-
LANP
(8W-51-7)
C333
Ll 18VT/BK- Ll 18VT/BK-
LEFT
BACK-UP
LANP
(8W-51-7)
8050cd80 J968W-9
8W-70 SPLICE INFORMATION 8W - 70 - 39
LEFT TAIL,
STOP AND
€333 C129 SPLICE
TURN SIGNAL L7 1 8 B K / Y L — « - L7 1 8 B K / Y L - | «—L7 18BK/YL- 1
S106
LAMP L7 (8W-70-4)
(8W-51-5) 18BK
YL
RIGHT TAIL,
€329 €342 RIGHT
STOP AND
L7 1 8 B K / Y L — » - L7 1 8 B K / Y L -
LICENSE
TURN SIGNAL L7 18BK/YL <f- L7 1 8 B K / Y L -
$314
~~ LANP
LANP <8W 51-4,10)
(8W-51-5)
WITH
DUAL REAR
WHEELS
L7
18BK SPLICE
YL
L7 1 8 B K / Y L - $406
(8W-70-42)
€343 L J
—»—-18BK-
YL
LEFT
L/ 18BK/YL- LICENSE
LANP
(8W-51-4)
TURN
C129 L62 C133 L62 SIGNAL/
-18BR- -18BR- HAZARD
PK PK SWITCH
(8W-52-5)
L62
18BR
PK
RIGHT TAIL.
TRAILER €331 $315* L62 €329 L62 STOP AND
TOM •L62 18BR/PK- L62 18BR/PK- . —-18BR- Ay -18DG- TURN
(8W-54-4) PK BR SIGNAL LANP
(8W-51-5)
(8W-52-6)
TURN
SIGNAL/
HAZARD
SWITCH
(8W-52-5)
L63
18DG
RD
LEFT TAIL,
TRAILER €331 S316* L63 C333 L63 STOP AND
TOW •L63 18DG/RD (( L63 18DG/RD - i ~ -18DG- -18DG- TURN
RD BR SIGNAL LANP
(8W-54-4)
(8W-51-5)
C8W-52-6)
*WITH TRAILER TOW

8050cd81 J968W-9
8W - 7 0 - 4 0 • 8W-70 SPLICE INFORMATION BR
JOINT
C208 C217 PARK CONNECTOR
LAMP
)>— 17 2 0 B K / Y L (f- SWITCH
(5) OUTPUT
LEFT OUTBOARD
CLEARANCE L7 18BK/YL
LAMP
(8W-50-6)
RIGHT
LEFT OUTBOARD OUTBOARD
IDENTIFICATION 17 18BK/YL L7 1 8 B K / Y L - CLEARANCE
LAMP LAMP
(8W-50-6)
(8W-50-6)
OVERHEAD CONSOLE
RIGHT
PARK ; C338 OUTBOARD
LAMP L7 1 8 B K / Y L - IDENTIFICATION
L7 18BK/YL
SWITCH LAMP
OUTPUT i ( 2 ) ! (8W-50-6)
WITH
HIGH-LINE
GND i—))•- CLUSTER CENTER
IDENTIFICATION
(11) LAMP
(8W-50-6)
Z4
18BK
CENTER
IDENTIFICATION
WITH LAMP
HIGH-LINE (8W-50-6)
RIGHT LEFT CLUSTER
VISOR/ VISOR/
VANITY VANITY
LAMP LAMP
(8W-44-4) (8W-44-4) L E F T OUTBOARD
OVERHEAD Z4 18BK- CLEARANCE LAMP
MAP/COURTESY (8W-50-6)
LAMP
(8W-49-5)
RIGHT OUTBOARD
Z4 18BK CLEARANCE LAMP
(8W-50-6)
L E F T OUTBOARD
1
IDENTIFICATION
— Z 4 183K-
LAMP
(8W-50-6)
RIGHT OUTBOARD
DAY/NIGHT IDENTIFICATION
Z4 18BK" LAMP
MIRROR Z4 2 2 B K = ^ _
(8W-44-9)
7
WITH
S319**
(8W-50-6)
HIGH-LINE
* WITH CLEARANCE AND I . D . LAMPS
CLUSTER * * WITH CONSOLE
8050cd82 J968W-9
WITH
LOW-LINE
CLUSTER
OVERHEAD
MAP/COURTESY
-Ml 20PK- LAMP
(8W-49-5)
OVERHEAD
CONSOLE
C20S SPLICE
S320"
18PK- M l 20PK )> M l 20PK- S205
(8W-70-28)
€353
RIGHT VISOR/
M l 20PK ({ Ml 20PK- VANITY LAMP
C8M-44-4)
€352 LEFT VISOR/
M l 18PK- M l 20PK ((——Ml 20PK- V A N I T Y LAMP
C8M-44-4)
SPLICE
-Z13 18BK ^ • S312
J< C 3 3 3 C8W-70-38)
T
Z13
18BK
I LEFT T A I L ,
LEFT j S 4 0 1 S T O P AND
BACK-UP ^ Z13 18BK - # Z13 18BK «« TURN
L A M P
S I G N A L LAMP
C8W-S1 7 ) (8W-51-5)
(8W-52-6)
SPLICE
- Z 1 3 18BK • S312
vI7c329 (8W-70-38)
T
Z13
18BK
I RIGHT T A I L ,
RIGHT I S 4 Q g S T O P AND
BACK-UP „ ^ Z13 18BK # Z13 18BK * TURN
L A M P
S I G N A L LAMP
<8W-51-7) (8W-51-5)
C8H-52-6)
BATTERY S403 HEATED I N T A K E

POSITIVE A I R SYSTEM
-A19 1 2 B K - •A19 6BK-
TERMINAL R E L A Y NO. 1
(WITH (8W-30-48)
DIESEL ENG)
(8W-30-48)
S404 HEATED I N T A K E
A8 6BK A I R SYSTEM
•A8 12BK-
R E L A Y NO. 2
(8W-30-48)
* WITH CONSOLE
8050cd83 J968W-9
S405*
1
Z13 Z13 Z13 Z13 Z13
Z13
Z13 C405 C4Q4 18BK C343 C402 C403
18BK
Z13 Z13 Z13 Z13 Z13

SPLICE
S312 LEFT RIGHT
RIGHT REAR LEFT REAR LEFT FORWARD FORWARD
(8W-70-38)
FENDER FENDER LICENSE FENDER FENDER
mm LANP LANP LANP LANP
(8W-51-12) (8W-51-10) SPLICE
(8W-51-12) (8W-51-12) (8W-51-12)
S314
(8W-70-39)
L7 L7 L7 L7 L7
YL YL YL YL YL
L7
C4Q5 C404 18BK C343 C402 C403
YL
L7 L7 L7 L7 L7
YL YL YL YL YL
L7 18BK/YL"
S406*
C406
$407<
L7 18BK/YL-
L7 L7
Z13
18BK 18BK
18BK
YL YL
RIGHT LEFT
TAILGATE TAILGATE
LAMP LANP
C8W-S1-J.I1 (8W-51-11)
Z13 Z13
18BK 18BK
$408*
* WITH DUAL REAR WHEELS
8050cd85 J968W-9
BR - 8W-70 SPLICE INFORMATION SW - 70 - 43
C105 SPLICE
Zl 20BK- mm
(8W-70-3)
Zl
20BK
L E F T FOG S409* R I G H T FOG

LAMP i Zl 20BK- Zl 20BK- LAMP
(8W-50-10) 8W-50-10)
* WITH FOG LAMPS

8050cd86 J968W-9
BR _ _ _ _ _ _ 8W - 80 CONNECTOR PIN-OUTS — - - 3W - 80 - 1
8W-80 C O N N E C T O R P I N - O U T S
INTRODUCTION
The pages referenced i n this section show the con
nector, the circuits i n the connector, and the pin that
circuit occupies. Individual connector numbers are
referenced on diagram pages throughout Group 8W.
8W-80-2- 8W-80 CONNECTOR PIN-OUTS BR
DIAGRAM INDEX
Connector Pap Connector Page
C101 8W-80-4 C155 8W-80-32
C102 8W-80-4 C156 8W-80-32
C103 8W-80-4 C157 8W-80-32
C104 . 8W-80-4 C158 8W-80-33
C105 8W-80-4 C159................... 8W-80-33
C106 8W-80-5 C160 8W-80-33
C107 8W-80-5 C161 8W-80-33
C108.... 8W-80-5 C162. .. 8W-80-34
C109 8W-80-5 C163. 8W-80-34
C110 8W-S0-5 C164. 8W-80-34
C111 8W-80-6 C165 8W-80-34
C112 8W-80-6 C167 8W-80-35
C113 8W-80-6 C168..................................... 8W-80-35
C114 8W-80-6 C169 8W-80-35
C115 8W-80-6 C170 8W-80-35
C116.. 8W-80-7 C171 8W-80-35
C117 8W-80-7 C172 8W-80-36
C118 8W-80-7 C173. 8W-80-36
C119 8W-80-7 C174 8W-80-36
C120. 8W-80-8 C175....... 8W-80-36
C121 8W-80-8 C176.................... 8W-80-36
C122 8W-80-9 C177 8W-80-37
C123.. • 8W-80-9 C178......... 8W-80-37
C124 8W-80-9 C179 8W-80-37
C125 8W-80-10 C180 8W-80-37
C126. 8W-80-10 C181 8W-80-37
C127... 8W-80-11 C182........................ 8W-80-37
C128 8W-80-11 C183... 8W-80-38
C129.. 8W-80-11 C184 8W-80-38
C130 8W-80-12 C185. 8W-80-38
C131 8W-80-12 C186.................. 8W-80-38
C132... 8W-80-12 C187 8W-80-39
C133... 8W-80-13,14 C188 8W-80-39
C134 8W-80-15 C189 8W-80-39
C135.. 8W-80-15,16,17,18 C190 8W-80-39
C136 8W-80-19, 20, 21, 22 C191 ,. 8W-80-39
C137 8W-80-23, 24, 25, 26 C192. ...... 8W-80-40
C138... 8W-80-27 C193 8W-80-40
C139... 8W-80-27 C194... 8W-80-40
C140... 8W-80-28 C195 8W-80-40
C141 8W-80-28 C201 8W-80-41
C142 8W-80-28 C202 8W-80-41
C143... 8W-80-28 C203 8W-80-41
C144... 8W-80-29 C204 ... 8W-80-42
C145 8W-80-29 C205 8W-80-42
C146 8W-80-29 C206 8W-80-42
C147 8W-80-29 C207 8W-80-42
0148... 8W-80-30 C208 8W-80-43
C149................ 8W-80-30 C209..................................... 8W-80-43
C150 8W-80-31 C210 8W-80-44
C151 8W-8Q-31 C212 8W-80-44
C152.;.. 8W-80-31 C213...... 8W-80-45
C153... 8W-80-32 C214 8W-80-45
C154 8W-80-32 C215 8W-80-45
8050cd88 J968W-9
BR 8W-80 CONNECTOR PIN-OUTS 8W - 80 • 3
DIAGRAM INDEX
Connector Page Connector Page
C216 8W-80-46 C 3 3 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-59
C217....... 8W-80-46 C333 8W-80-59
C218 8W-80-46 C334 8W-80-59
C219 8W-80-47 C335 8W-80-59
C223 8W-80-47 C 3 3 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-60
C224 8W-80-48 C337 8W-80-60
C225 8W-80-48 C338 8W-80-60
C226 8W-80-48 C339 8W-80-60
C227 8W-80-49 C340 8W-80-61
C228 8W-80-49 C341 8W-80-61
C229 3W-80-49 C342 8W-80-61
C230 8W-80-50 C343 8W-80-61
C231 8W-80-50 C345 8W-80-62
C232 8W-80-50 C346 8W-80-62
C233 . 8W-80-51 C347 8W-80-62
C234 8W-80-51 C348 8W-80-63
C235 8W-80-51 C352 8W-80-63
C236 8W-80-51 C353 8W-80-63
C237 8W-80-51 C401 8W-80-63
C238 8W-80-52 C402 8W-80-64
C239 8W-80-52 C403 8W-80-64
C240 8W-80-52 C404 . 8W-80-64
C301 8W-80-53 C405 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-64
C302 8W-80-53 C406 8W-80-64
C303 8W-80-53 C407 8W-80-65
C304 8W-80-53 C409 8W-80-65
C305 8W-80-53 C410 8W-80-65
C306 8W-80-54 C411 8W-80-65
C307 8W-80-54 C412 8W-80-66
C308 8W-80-54 C413 8W-80-66
C309 8W-80-54 C414 8W-80-66
C310 . . . . . . . . . . 8W-80-54 C415 8W-80-66
C311 8W-S0-55 C416 8W-80-66
C312 8W-80-55 C417 . . . . . . . . . 8W-80-67
C313 8W-80-55 C418 8W-80-67
C314 8W-80-55 C419 8W-80-67
C315 8W-80-55 C420 8W-80-67
C316 8W-80-56 C421 8W-80-67
C317.... 8W-80-56 C422 8W-80-68
C318 8W-80-56 C423 8W-80-68
C319 8W-80-56 C424 8W-80-68
C320 8W-80-56 C425 8W-80-68
C321 8W-80-57 C426 8W-80-68
C322 8W-80-57 C427 8W-80-69
C323 8W-80-57 C428 8W-80-69
C324 SW-80-57 C429 8W-80-69
C325 8W-80-57 C430 8W-80-69
C326 8W-80-58 C431 8W-80-70
C327 8W-80-58 C432 8W-80-70
C328 8W-80-58 C433 8W-80-70
C329 8W-80-58 C434 8W-80-70
C330 8W-80-58 C 4 3 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-71
C331 8W-80-59 C436 8W-80-71
8050cd89 J968W-9
8W*80»4- 8W-80 CONNECTOR PIN-OUTS 1
-BR
C101
1 2 3 BLACK
CAV CIRCUIT FUNCTION
OOP 1 Z l 18BK GROUND
2 L7 18BK/YL PARK LAMP SWITCH OUTPUT
£=1 3 L60 18LG/TN RIGHT TURN SIGNAL
RIGHT PARK/
TURN SIGNAL
LAMP
BLUE
C102
A Zl 20BK GROUND
B L4 16VT/WT DIMMER SWITCH LOW BEAM OUTPUT
C L3 16RD/0R DIMMER SWITCH HIGH BEAM OUTPUT
RIGHT
HEADLAMP
BLACK
C103
1 R48 18TN RIGHT IMPACT SENSOR LINE 2
2 R46 18BR/LB RIGHT IMPACT SENSOR LINE 1
RIGHT AIRBAG
SENSOR
GREEN
C104
1 B6 20WT/DB RIGHT FRONT WHEEL SPEED SENSOR (-)
2 B7 20WT RIGHT FRONT WHEEL SPEED SENSOR (+)
RIGHT FRONT
WHEEL SPEED
SENSOR
BLACK am BLACK
CAV CIRCUIT CAV CIRCUIT
1 L39 20LB 1 L39 20LB
2 L39 20LB 2 L39 20LB
1 2 3
3 Zl 20BK 3 Zl 20BK
3 2 1
8050cd8a J968W-9
8W-80 CONNECTOR PIN-OUTS 8W - 80 - 5
BLACK BLACK
C106

1 G107 18BK/GY 1 G107 20BK/GY
2 Zl 18BK 2 Zl 20BK
BLACK C107

1 VIO 18BR WASHER PUMP CONTROL SWITCH OUTPUT
2 Zl 20BK GROUND
WINDSHIELD WASHER
PUMP MOTOR
•BLACK C108

1 G29 18BK/TN WASHER FLUID SWITCH SENSE
2 1
2 Zl 18BK GROUND
LOW WASHER FLUID
SWITCH
C109
BLACK
1 V36 20TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
2 V35 20LG/RD SPEED CONTROL VENT SOLENOID CONTROL
3 V30 20DB/RD SPEED CONTROL ON/OFF SWITCH OUTPUT
VEHICLE 4 Zl 20BK GROUND
SPEED CONTROL
SERVO
BLACK C110

1 R49 18LB/WT LEFT IMPACT SENSOR LINE 2
2 R47 18DB/LB LEFT IMPACT SENSOR LINE 1
LEFT AIRBAG
SENSOR
8050cd8b J968W-9
8W - 80 - 6 8W-80 CONNECTOR PIN-OUTS BR
cm
BLACK CAV CIRCUIT FUNCTION
1 A142 20D6/0R AUTO SHUT DOWN RELAY OUTPUT
2 - -
7 • • • • • • •
3 K22 200R/DB THROTTLE POSITION SENSOR SIGNAL
14 • • • • • • •
4 K321 20BK/PK EGR I A T ( + )
EGR 5 K204 20BK/WT EGR I A T (-)
CONTROL
MODULE 6 K2 20TN/BK EGR ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
7 K304 20BK/LG EGR COOLANT TEMPERATURE SENSOR GROUND
8 - -
9 D28 20LG/RD EGR OUTPUT SIGNAL
10 Z12 18BK/TN GROUND
11 D29 20PK/DG EGR DIAGNOSTIC SIGNAL
12 K6 20VT/WT 5 VOLT SUPPLY
13 - -
14 K35 18GY/YL EGR SOLENOID CONTROL
CU2
1 2 3 -BLACK
£H3 1
2
Z l 18BK
L7 18BK/YL
GROUND
PARK LAMP SWITCH OUTPUT
3 161 18LG/TN LEFT TURN SIGNAL
LEFT PARK/
TURN SIGNAL LAMP
BLUE C113
A Zl 20BK GROUND
B L4 16VT/WT DIMMER SWITCH LOW BEAM OUTPUT
C L3 16RD/0R DIMMER SWITCH HIGH BEAM OUTPUT
LEFT
HEADLAMP
BLACK
C1I4
1 G31 18VT/LG AMBIENT TEMPERATURE SENSOR SIGNAL
2 G32 18BK/VT SENSOR GROUND
AMBIENT
TEMPERATURE
SENSOR
BLACK
C115
1 X2 18DG/RD HORN RELAY OUTPUT
HIGH 2 Z l 18BK GROUND
NOTE HORN
8050cd8c J968W-9
8W-8I CONNECTOR PiN-OUTS 8W - 80 - 7
BLACK C116

1 X2 18DG/RD HORN RELAY OUTPUT
2 Zl 18BK GROUND
LOW
NOTE HORN
BLACK C117 (WITH RWAL)

A B101 18LG/WT RWAL ISOLATION SOLENOID
B Z8 16BK/PK GROUND
C Bill 18LB/BK RWAL RESET SWITCH
RWAL D B108 18WT RWAL DUMP SOLENOID
VALVE
BLACK
C117 (WITH ABS)

A B252 18BR/TN REAR ISOLATION VALVE CONTROL
B B120 12BR/WT ABS PUMP MOTOR RELAY OUTPUT
C B19 20LB REAR VALVE RESET SWITCH SENSE
RWAL D B254 16DG/0R REAR DUMP VALVE CONTROL
VALVE
BLACK
C118 (WITH ABS)

1 B8 20RD/GY LEFT FRONT WHEEL SPEED SENSOR (-)
LEFT FRONT 2 B9 20RD LEFT FRONT WHEEL SPEED SENSOR ( + )

WHEEL SPEED
SENSOR
BLACK BLACK
C119
m
1 A15 16PK* 1 A15 16PK
1 A15 20BK** 2 T40 12BR
2 T40 12BR
* WITH GAS ENG

* * WITH DIESEL ENG
J968W-9
8W-80 -8 8W-80 CONNECTOR PIN-OUTS BR
BLACK C120

A IB 10BK/PK GROUND
B B60 12LB/BK PUMP/MOTOR CONTROL
ABS
2-WAY
POWER FEED
C121 (WITH ABS)

1 B113 20RD/VT RIGHT REAR WHEEL SPEED SENSOR ( + )
2 B7 20WT RIGHT FRONT WHEEL SPEED SENSOR ( + )
3 B9 20RD LEFT FRONT WHEEL SPEED SENSOR ( + )
4 B116 20GY ABS PUMP MOTOR RELAY CONTROL
BLACK
1 14 26 5 B5 20VT/RD LEFT FRONT RESET SWITCH SENSE
6 A20 18RD/DB FUSED I G N I T I O N SWITCH OUTPUT (RUM)
7 A20 18RD/DB FUSED I G N I T I O N SWITCH OUTPUT (RUN)
8 G107 20BK/GY 4WD SENSE
9 V40 20WT/PK BRAKE SWITCH SENSE
10 D12 200R SCI TRANSMIT
11 Dll 20WT/RD SCI RECEIVE
13 B47 20RD/LB ABS WARNING LAMP RELAY CONTROL
14 B114 20WT/VT RIGHT REAR WHEEL SPEED SENSOR (- )
15 B6 20WT/DB RIGHT FRONT WHEEL SPEED SENSOR ( )
16 B8 20RD/GY LEFT FRONT WHEEL SPEED SENSOR (-)
18 B18 20VT/LG RIGHT FRONT RESET SWITCH SENSE
13 25 37 19 B19 20LB REAR VALVE RESET SWITCH SENSE
CONTROLLER 20 17 18BK/RD GROUND
ANTI-LOCK 21 A20 18RD/DB FUSED I G N I T I O N SWITCH OUTPUT (RUN)
BRAKE
22 - -
23 - -
24 G19 20LG/RD ABS WARNING LAMP DRIVER
25 69 20GY/BK RED BRAKE WARNING LAMP DRIVER
26 B254 16DG/0R REAR DUMP VALVE CONTROL
27 - -
28 B252 18BR/TN REAR ISOLATION VALVE CONTROL
_.
29 -
30 B248 16DG/WT RIGHT FRONT DUMP VALVE CONTROL
31 -
32 - -
33 B249 18WT/TN RIGHT FRONT ISOLATION VALVE CONTROL
34 B120 14BR/WT ABS PUMP MOTOR RELAY OUTPUT
35 B243 16DG/BK LEFT FRONT DUMP VALVE CONTROL
36 -
37 B245 18WT/LG LEFT FRONT ISOLATION VALVE CONTROL
8050cd8e J968W-9
8W-80 CONNECTOR PIN-OUTS 8W - 80 - i
BLACK €121!
5 (O o u
o o O) 1 B60 12LB/BK PUMP/MOTOR CONTROL
2 B249 18WT/TN RIGHT FRONT ISOLATION VALVE CONTROL
10 [O Q o n o O,
3 B248 16DG/WT RIGHT FRONT DUMP VALVE CONTROL
HYDRAULIC 4 B18 20VT/LG RIGHT FRONT RESET SWITCH SENSE
CONTROL 5 B120 12BR/WT ABS PUMP MOTOR RELAY OUTPUT
UNIT
7 B245 18WT/LG LEFT FRONT ISOLATION VALVE CONTROL
8 B243 16DG/BK LEFT FRONT DUMP VALVE CONTROL
9 B5 20VT/RD LEFT FRONT RESET SWITCH SENSE
C123
BLACK Zl 18BK GROUND
1
Zl 18BK GROUND
2 Zl 12BK** GROUND
2 Zl 14BK* GROUND
Zl 18BK GROUND
3
Zl 18BK GROUND
GROUND 4 Zl 14BK® GROUND
JOINT
4 Zl 12BK" GROUND
)
5 Zl 18BK GROUND
0124
BLACK
1 V4 18RD/YL WIPER SWITCH HIGH SPEED OUTPUT
_ J l ] % L _
2 V5 18DG/YL WIPER SWITCH MODE SENSE
m m 3 V6 18DB/BK FUSED I G N I T I O N SWITCH OUTPUT
WINDSHIELD 4 V3 18BR/WT WIPER SWITCH LOW SPEED OUTPUT
WIPER MOTOR
• WITH LOW-LINE CLUSTER

•• WITH MEDIUM-LINE AND H I G H - L I N E CLUSTER
* WITH MEDIUM-LINE AND LOW-LINE CLUSTER
** WITH H I G H - L I N E CLUSTER
> WITH DIESEL ENG
J968W-9
8W - 80-10- 8W-80 CONNECTOR PIN-OUTS or.
C125
BLACK CAV
1
2
CIRCUIT
G14 18PK/BK*
T6 2 0 0 R / W T 0
r BLACK CAV
1
2
CIRCUIT
G14 18PK/BK
T6 220R/WT
4 [ • • • • 3
3
G54
T18 2OLG/OR
200R/BK"
0 •• •• •• •• 3 T18 22LG/0R
•••• 4
T 4 1 20BK/WT*
13 16 4 T 4 1 22BK/WT
16 13 Z12 2 0 B K / T N ~
u ir'
5 G86 18TN/0R** 5 G86 18TN/0R
6 G85 180R/BK** 6 G85 180R/BK
7 C13 20DB/OR 7 C13 22DB/OR
8 K51 20DB/YL 8 K51 22DB/YL
J>
V40 20WT/PK
9 V40 20WT/PK 9
V40 22WT/PK>
10 C90 18LG 10 C90 18LG
11 G12 20TN/YL 11 G12 20TN/YL
12 K118 20PK/YL 12 K118 20PK/YL
13 K4 2 0 B K / L B 13 K4 2 0 B K / L B
15 T16 18RD 15 T16 18RD
16 K30 20PK 16 K30 20PK
C126
GRAY CAV CIRCUIT GRAY CAV CIRCUIT

1 F18 18LG/BK 1 F18 18LG/BK
2 V32 20YL/RD 2 V32 20YL/RD
•••• 3 V37 20RD/LG ; iitIi 3 V37 20RD/LG
]•••
4 Z12 20BK/TN uu uu 4 Z12 20BK/TN
16 V-JJ ^
13
5 C3 18DB/BK 13 un:•c 16 5 C3 18DB/BK
6 Ll 18VT/BK 6 Ll 18VT/BK
7 V35 20LG/RD 7 V35 20LG/RD
8 G3 22BK/PK 8 G3 20BK/PK
9 V36 20TN/RD 9 V36 20TN/RD
10 LIO 18BR/LG 10 L10 18BR/LG
11 D20 20DG 11 D20 20DG
12 D21 D20PK/DB 12 D21 20PK/DB
13 G24 20GY/PK 13 G24 20GY/PK+
14 K226 20DB/WT* 14 K226 20DB/WT*
15 Zll 20BK/WT 15 Zll 20BK/WT
+ WITH GAS ENG

5
WITH RWAL
) }
WITH ABS
• WITH AUTO TRANS
•• WITH MAN TRANS (EXCEPT HEAVY DUTY, DIESEL ENG AND 8 . 0 L ENG)
* NOT FUNCTIONAL ON DIESEL ENG
** ^ WITH DIESEL ENG
8050cd90 J968W-9
BR 8W-80 CONNECTOR PIN-OUTS 8W-80-11
C127
LT GRAY LT GRAY
1 A142 14DG/0R 1 A142 14DG/0R
G21 22GY/LB O o o o O 5 2 G21 20GY/LB
5 |fo~^-^~ol] 1 2
3 K31 20BR/WT O o o o O 10 3 K31 20BR/WT*
10 lo o OHO O) 6 n—J
4 G60 16GY/YL*
4 G60 22GY/YL }
4 660 18GY/YL
5 T40 12BR 5 T40 12BR>
6 A14 16RD/WT 6 A14 16RD/WT
7 G20 22VT/YL 7 G20 18VT/YL
#
8 G6 16GY
8 G6 22GY
8 G6 186Y>
9 G7 22WT/0R 9 G7 20WT/0R
C128
BLACK BLACK
3 jT 3
1 B113 20RD/VT nrin 1 B113 20RD/VT
2 2 B114 20WT/VT 1 2 B114 20WT/VT
5 3 Z13 12BK*
•EEb 4 3 Z13 16BK*
8 3
4
Z13
Zll
16BK**
20BK/WT
• • 7 3
4
Z13
Zll
12BK**
20BK/WT
5 G4 20DB/0R 5 G4 20DB
6 B40 14LB 6 B40 14LB
7 K4 20BK/LB 7 K4 20BK/LB
8 K104 20DB/WT®® 8 K226 20DB/WT~
C129
BLACK BLACK
3
nnn 1 L7 18BK/YL 1 L7 18BK/YL
1 2 - 2 -
4 3 L76 12BK/0R 3 L76 12BK/0R
D D
c-i 7 4 L63 18DG/RD 4 L63 18DG/RD
• • 5 Ll 18VT/BK 5 Ll 18VT/BK
6 A6 14RD/TN 6 A6 14RD/TN
7 L62 18BR/PK 7 L62 18BR/PK
8 A61 16DG/BK- 8 A61 16DG/BK"
> WITH DIESEL ENG

•• NOT FUNCTIONAL ON DIESEL
• WITH GAS ENG
* WITHOUT TRAILER TOW
** WITH TRAILER TOW
8050cd91 J968W-9
aw-80-12 -8W-80 CONNECTOR PIN-OUTS' -BR
CI30
BLACK
1 Zl 20BK GROUND
2 Ml 20PK FUSED B( + )
UNDERHOOD
LAMP
C131
BLACK
1 L3 16RD/0R DIMMER SWITCH HIGH BEAM OUTPUT
5 'O o o oy
O" 2 -
10 O o o o
n Q (
3 Gil 20WT/BK PARK BRAKE SWITCH SENSE
4 G34 18RD/GY HIGH BEAM INDICATOR LAMP DRIVER
DAYTIME RUNNING 5 LIO 18BR/LG FUSED I G N I T I O N SWITCH OUTPUT (RUN)
LAMP MODULE 6 A3 12RD/LG FUSED B ( + )
7 - -
8 Zl 18BK GROUND
9 Zl 18BK GROUND
10 L4 16VT/WT DIMMER SWITCH LOW BEAM OUTPUT
C132 (WITH AUTO TRANS)

GREEN
GREEN
1 T141 14YL/RD 1 T 1 4 1 20YL/RD
BYPASS
2 A41 18DB/YL
m
BYPASS
2 T 1 4 1 20YL/RD
JUMPER JUMPER
GREEN C132 (WITH MAN TRANS)

1 T141 14YL/RD ENGINE STARTER MOTOR RELAY DRIVER
2 A41 18DB/YL FUSED I G N I T I O N SWITCH OUTPUT (START)
CLUTCH PEDAL
POSITION SWITCH
8050cd92 J968W-9
BR 8W-80 CONNECTOR PIN-OUTS- 8W-80-13
C133

BLACK BLACK
1 R47 18DB/LB 1 R47 18DB/LB
2 G12 22TN/YL 1 12 2 G12 20TN/YL
12
24 ruuuuuu uuuuuu i
13
3
4
G4 22DB
L62 18BR/PK
13 mnauuu uuuuatni 24 3 G4 20DB
25 DDDDDDDDDDDD 36 4 L62 18BR/PK
36 DDDDDD DDDDDD 25
40 DD
DDQDDDDDDDDD
37
5
6
L63
T6
18DG/RD
220R/WT
37 DDDDDDDDDDDD
DDODD
40 5
6
L63
T6
18DG/RD
220R/WT
44
O DD 41 7 T18 22LG/0R 41
DD O DD 44 7 T18 22LG/0R
48
60
DD 45
49
8
9
G20 22VT/YL
G21 2 2 G Y / L B
45
49
DD DD 48
60
8
9
G20 22VT/YL
G21 22GY/LB
DDDDDD DDDDDD 10 G24 22GY/PK DDDDDD DDDDDD 10 G24 20GY/PK
72 DDDDDD DDDDDD 61
11 L35 22BR/WT
61 DDDDDD DDDDDD 72
11 L35 22BR/WT
84 73
innnnnn nnnnnn 12 R48 18TN
73
.nnnnnn nnnnnnj 84 12 R48 18TN
13 L50 18WT/TN 13 L50 18WT/TN
14 C90 22LG 14 C90 18LG
15 G3 22BK/PK 15 G3 22BK/PK
16 X3 2 2 B K / R D *
A A
16 X3 22BK/RD
16 X3 2 0 B K / R D
17 M2 20YL 17 M2 18YL
18 G6 22GY 18 G6 22GY
19 G60 22GY/YL 19 G60 22GY/YL
20 G7 20WT/0R 20 G7 22WT/0R
21 Z12 2QBK/TN 21 Z12 20BK/TN
23 A41 18DB/YL 23 A41 18DB/YL
24 L39 18LB 24 L39 20LB
26 G107 20BK/GY+
26 G107 20BK/GY
26 G107 22BK/GY++
27 G34 18RD/GY 27 G34 18RD/GY
28 G9 18GY/BK*
28 G9 22GY/BK
28 G9 2 0 G Y / B K * *
29 629 22BK/TN** 29 G29 18BK/TN*
30 F18 2 2 L G / B K 30 F18 2 0 L G / B K
31 V30 20DB/RD 31 V30 20DB/RD
32 Gil 22WT/BK 32 Gil 20WT/BK
34 Ml 20PK 34 Ml 20PK
35 V40 20WT/PK++
35 V40 22WT/PK
35 V40 22WT/PK+
36 Z6 18BK/0R 36 Z6 18BK/0R
37 V3 18BR/WT 37 V3 18BR/WT
38 L3 16RD/0R 38 L3 16RD/0R
39 L4 16VT/WT 39 L4 16VT/WT
40 L7 1 8 B K / Y L 40 L7 1 8 B K / Y L
(C133 CONTINUED ON NEXT PAGE)
• WITH SPEED CONTROL, H I G H - L I N E CLUSTER

A WITH POWER WINDOWS AND POWER LOCKS
•A WITHOUT POWER WINDOWS AND POWER LOCKS
+ WITH RWAL
++ WITH ABS
* WITH RWAL WITHOUT D I E S E L ENG
** WITH D I E S E L ENG OR ABS
8050cd93 J968W-9
8W - 80 - 1 4
C 1 3 3 (CONTINUED)
BLACK CAV CIRCUIT BLACK CAV CIRCUIT
41 A20 18RD/DB 41 A20 18RD/DB
12 1 1 DUUUUU DDUUDD 12
24
36
r u u u u u u uuLJunLfn
13
25
42
43
A l 12RD
A2 12PK/BK 13 DDDDDDDDDDDD
DDDDDD DDDDDD
24
42
43
A l 12RD
A2 12PK/BK
DDDQDD DDDDDD 44 L9 18BK/VT 25 36
44 L9 18BK/VT
40 DDDDDD DDDDDD 37
45 V4 16RD/YL 37 DD DD 40 45 V4 18RD/YL
DDIo DD DD O DD
DD • D
44 41 46 B108 18WT 41 44 46 B108 18WT
47 A3 12RD/LG 47 A3 12RD/LG
48
60 DD
45
49
48 A7 12RD/BK
45
49
DD DD
DDDDDDDDDDDD
48
60
48 A7 12RD/BK
49 Z2 18BK/LG 49 Z2 18BK/LG
72 DDDDDD DDDDDD 61 50 G19 22LG/RD 61 DDDDDDDDDDDD 72 50 G19 20LG/RD
84 DDDDDD DDDDDD 73 51 B101 18LG/WT 73 innnnnn nnnnnm 84 51 B101 18LG/WT
innpnpn nnnnnnJ 52 Bill 22LB/BK 52 Bill 18LB/BK
53 B113 20RD/VT 53 B113 20RD/VT
54 B114 22WT/VT 54 B114 20WT/VT
55 R46 18BR/LB 55 R46 18BR/LB
56 56
57 57 _
58 58 R49 18LB/WT
>
59 G31 22VT/LG
R49 18LB 59 G31 18VT/LG >
60 G32 22BK/LB> 60 G32 18BK/VT >
61 11 18BK/LG 61 Z2 18BK/LG
62 LIO 20BR/LG"
62 LIO 22BR/LG
62 LIO 1 8 B R / L G *
....
63 - 63
64 V6 18DB/P>:< 64 V6 18DB/BK
65 V5 18DG/YL 65 V5 18DG/YL
66 VIO 18BR 66 VIO 18BR
67 G14 20PK/BK 67 G14 18PK/BK
68 G86 20TN/0R 68 G86 18TN/0R
69 L61 18LG/YL 69 L61 20LG/YL
70 L60 18TN/BK 70 L60 20TN/BK
71 G85 200R/BK 71 G85 180R/BK
72 72 -
73 D21 20PK/DB 73 D21 20PK/DB
74 D20 20DG 74 D20 20DG
75 - 75 -
76 D12 220R 76 D12 200R
77 Dll 22WT/RD 77 Dll 20WT/RD
78 - 78 -
79 V32 22YL/RD 79 V32 20YL/RD
80 V37 22RD/LG 80 V37 20RD/LG
81 K4 18BK/LB 81 K4 2 0 B K / L B
82 - 82
83 - 83 -
84 84 -
J
WITH OVERHEAD CONSOLE
&
WITHOUT DRL
e e
WITH DRL
8050cd94 J968W-9
BR 8W-80 CONNECTOR PIN-OUTS- 8W - 80 - 1 5
BLACK C134 (WITH DIESEL ENG)

1 Z l 18BK GROUND
2 69 20GY/BK RED BRAKE WARNING LAMP DRIVER
VACUUM SENSOR 3 A20 18RD/DB FUSED I G N I T I O N SWITCH OUTPUT (RUN)
C135 ( 3 . 9 L ENG)
BLACK CIRCUIT
CAV FUNCTION
Al -
A2 F18 20LG/BK FUSED I G N I T I O N SWITCH INPUT (START/RUN)
All ooooooooooo Al A3 -
A21 oooooooooo A12 A4 K4 20BK/LB SENSOR GROUND
ooooooooooo
A32 A22 A5 - -
A6 T 4 1 20BK/WT PARK/NEUTRAL POSITION SWITCH SENSE
A7 K19 16BK/GY I G N I T I O N COIL NO. 1 DRIVER
POWERTRAIN
CONTROL A8 K24 20GY/BK CRANK POSITION SENSOR SIGNAL
MODULE A9 - --
(CONNECTOR A )
A10 K60 18YL/BK IDLE A I R CONTROL MOTOR NO. 2 DRIVER
All K40 18BR/WT IDLE A I R CONTROL MOTOR NO. 3 DRIVER
A12 - -
A13 - ...
A14 -
A15 K21 18BK/RD INTAKE A I R TEMPERATURE SIGNAL
A16 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
A17 K6 20VT/WT 5 VOLT SUPPLY
A18 K44 20TN/YL CAMSHAFT POSITION SENSOR SIGNAL
A19 K39 18GY/RD IDLE A I R CONTROL MOTOR NO. 1 DRIVER
A20 K59 18VT/BK IDLE A I R CONTROL MOTOR NO. 4 DRIVER
A21 - -
A22 A14 16RD/WT FUSED ( B + )
A23 K22 180R/DB THROTTLE POSITION SENSOR SIGNAL
A24 K141 18TN/WT UPSTREAM HEATED OXYGEN SENSOR SIGNAL
A25 K341 180R/BK DOWNSTREAM HEATED OXYGEN SENSOR SIGNAL
A26 -
A27 Kl 18DG/RD MAP SENSOR SIGNAL
A28 - -
A29 - -
A30 - -
A31 Z12 14BK/TN GROUND
A3 2 Z12 14BK/TN GROUND
8050cd95 J968W-9
8W - 80 -16 8W-80 CONNECTOR PIN-OUTS BR
C135 ( 5 . 2 L / 5 . 9 L ENG)
BLACK
Al -
All ooooooooooo Al A3 - -
A21 oooooooooo A12 A4 K4 20BK/LB SENSOR GROUND
ooooooooooo
A32 A22 A5 -
A6 T41 20BK/WT PARK/NEUTRAL POSITION SWITCH SENSE
POWERTRAIN A7 K19 16BK/GY I G N I T I O N COIL NO. I DRIVER

CONTROL A8 K24 20GY/BK CRANK POSITION SENSOR SIGNAL
MODULE A9 _ -
(CONNECTOR A) A10 K60 18YL/BK IDLE A I R CONTROL MOTOR NO. 2 DRIVER
All K40 18BR/WT IDLE A I R CONTROL MOTOR NO. 3 DRIVER
A12 _
A13
A14 -
A19 K39 18GY/RD IDLE A I R CONTROL MOTOR NO. 1 DRIVER
A21 - -
A22 A14 16RD/WT FUSED (B+)
A24 K141 18TN/WT* UPSTREAM HEATED OXYGEN SENSOR SIGNAL
A24 K41 18BK/DG" UPSTREAM HEATED OXYGEN SENSOR SIGNAL
A25 K341 180R/BK* DOWNSTREAM HEATED OXYGEN SENSOR SIGNAL
00
A26 K241 18BK/DG DOWNSTREAM HEATED OXYGEN SENSOR SIGNAL
A28 - _
A29
A30 - -
A3 2 Z12 14BK/TN GROUND
° WITHOUT HEAVY DUTY

0 0
WITH 5 . 9 L HEAVY DUTY
8050cd97 J968W-9
1
BR 8W-8D CONNECTOR PIN-OUTS- 8W^88-17
- BLACK C135 (8.0L ENG)

Al K32 18YL/GY IGNITION C O I L NO. 4 DRIVER
All ooooooooooo Al A2 F18 2 0 L G / B K FUSED IGNITION SWITCH INPUT (START/RUN)
A21 oooooooooo A12 K18 18RD/BK
ooooooooooo A3 IGNITION C O I L NO. 3 DRIVER
A32 A22 A4 K4 2 0 B K / L B SENSOR GROUND
A5 K43 18DG/6Y IGNITION C O I L NO. 5 DRIVER
A6 T41 20BK/WT PARK/NEUTRAL POSITION SWITCH SENSE
POWERTRAIN
CONTROL A7 K19 18BK/GY IGNITION C O I L NO. 1 DRIVER
MODULE A8 K24 20GY/BK CRANK POSITION SENSOR SIGNAL
(,C0NNECT0R A)
A9 K17 18DB/WT IGNITION C O I L NO. 2 DRIVER
A10 K60 1 8 Y L / B K I D L E A I R CONTROL MOTOR NO. 2 DRIVER
All K40 18BR/WT I D L E A I R CONTROL MOTOR NO. 3 DRIVER
A12 -
A13 - -
A14 -
A19 K39 18GY/RD I D L E A I R CONTROL MOTOR NO. 1 DRIVER
A21 -
A22 A14 16RD/WT FUSED (B+)
A24 K141 18TN/WT L E F T UPSTREAM HEATED OXYGEN SENSOR SIGNAL
A25 K341 180R/BK* POST CATALYST HEATED OXYGEN SENSOR SIGNAL
A26 K41 18BK/DG RIGHT UPSTREAM HEATED OXYGEN SENSOR SIGNAL
A28 -
0
A29 K441 18TN/RD PRE-CATALYST HEATED OXYGEN SENSOR SIGNAL
A30 - -
WITH CALIFORNIA
8050cd98 J968W-9
8W-80-18 •8W-80 CONNECTOR PIN-OUTS BR
BLACK C13S ( D I E S E L ENG)

Al -
All ooooooooooo Al
A21 oooooooooo A12
ooooooooooo . A3 .- -
A32 A22
A4 K4 20BK/LB SENSOR GROUND
A5 - -
A6 T 4 1 20BK/WT PARK/NEUTRAL POSITION SWITCH SENSE
POWERTRAIN
CONTROL A7 S21 20YL/BK A I R INTAKE HEATER RELAY NO. 1 CONTROL
MODULE A8 K24 20GY/BK ENGINE SPEED SENSOR SIGNAL
(CONNECTOR A )
A9 S22 200R/BK A I R INTAKE HEATER RELAY NO. 2 CONTROL
A10 -
All - -
A12 D28 20LG/RD EGR ON/OFF SIGNAL
A13 -
A14 _ -
A16 -
A18 - _
A19 - -
A20 -
A21 - -
A22 A14 16RD/WT FUSED ( B + )
A23 K22 20OR/DB THROTTLE POSITION SENSOR SIGNAL
A24 - ...
A25 - -
A26 - -
A27 Kl 20DG/RD WATER-IN-FUEL SENSOR SIGNAL
A28 _
A29 _ -
A30 - -
8050cd99 J968W-9
mm- 8W-80 CONNECTOR PiNÔOTS- 8 W - 8 0 19
WHITE C136 (3.9L ENG)

Bl T54 18VT TRANSMISSION TEMPERATURE SENSOR SIGNAL
Bll ooooooooooo Bl B2 _
B21 oooooooooo B12
ooooooooooo B3 - -
B32 B22 B4 Kll 18WT/DB INJECTOR NO. 1 DRIVER
B5 K13 18YL/WT INJECTOR NO. 3 DRIVER
B6 K38 18GY INJECTOR NO. 5 DRIVER
POWERTRAIN B7 - ...
CONTROL
MODULE B8 K88 20VT/WT VARIABLE FORCE SOLENOID CONTROL
...
(CONNECTOR B) B9
.....
BIO _
BIO K20 18DG GENERATOR F I E L D DRIVER
Bll G54 200R/BK* UPSHIFT LAMP DRIVER
Bll K54 200R/BK** TORQUE CONVERTER CLUTCH SOLENOID CONTROL
B12 K58 18BR/DB INJECTOR NO. 6 DRIVER
B13 - -
B14 - -
B15 K12 18TN INJECTOR NO. 2 DRIVER
B16 K14 1 8 L B / B R INJECTOR NO. 4 DRIVER
B17 _
B18 - -
B19 - -
B20 - -
B21 T60 20BR OVERDRIVE SOLENOID CONTROL
B22 K221 18TN/PK FUEL TEMPERATURE SENSOR SIGNAL
B23 - -
B24 - -
B25 T13 18DB/BK OUTPUT SHAFT SPEED SENSOR GROUND
B26 - -
B27 G7 20WT/0R VEHICLE SPEED SENSOR SIGNAL
B28 T14 18LG/BK OUTPUT SHAFT SPEED SENSOR SIGNAL
B29 T25 20LG/WT GOVERNOR PRESSURE SIGNAL
B30 K30 20PK TRANSMISSION RELAY CONTROL
B31 K7 180R 5 VOLT SUPPLY
B32 -
* WITH MAN TRANS (EXCEPT HEAVY DUTY AND D I E S E L )

** WITH AUTO TRANS
8050cd9a J968W-9
8W - 80 - 20 -8W-80 CONNECTOR PIN-OUTS • BR
WHITE C136 ( 5 . 2 L / 5 . 9 L ENG)

Bll ooooooooooo Bl
B2 K26 18VT/TN INJECTOR NO. 7 DRIVER
B21 oooooooooo B12 _
ooooooooooo B3 __
B32 B22
B4 Kll 18WT/DB INJECTOR NO. 1 DRIVER
B5 K13 18YL/WT INJECTOR NO. 3 DRIVER
POWERTRAIN B6 K38 18GY INJECTOR NO. 5 DRIVER

CONTROL B7 - -
(CONNECTOR B)
B9 - -
BIO K20 18DG GENERATOR FIELD DRIVER
Bll G54 2 0 0 R / B K * UPSHIFT LAMP DRIVER
Bll K54 2 0 0 R / B K * * TORQUE CONVERTER CLUTCH SOLENOID CONTROL
B13 K28 18GY/LB INJECTOR NO. 8 DRIVER
B14 - -
B16 K14 18LB/BR INJECTOR NO. 4 DRIVER
B17 - -
B18 - _
B19 - -
B20 _ ....

B22 K221 18TN/PK FUEL TEMPERATURE SENSOR SIGNAL
B23 _ -
B24 - -
B26 -
B32 K35 20GY/YL EGR SOLENOID CONTROL
* WITH MAN TRANS (EXCEPT HEAVY DUTY AND D I E S E L )

* * WITH AUTO TRANS
8050cd9b J968W-9
BR • 8W-80 CONNECTOR PIN-OUTS* 8W - 80 - 21
WHITE C13S (8.0L ENG)

B2 K26 18VT/TN INJECTOR NO. 7 DRIVER
B4 K l l 18WT/DB INJECTOR NO. 1 DRIVER
U[a|JJJ B5 K13 18YL/WT INJECTOR NO. 3 DRIVER
POWERTRAIN B6 K38 18GY INJECTOR NO. 5 DRIVER
CONTROL B7 -
(CONNECTOR B)
B9 - -

Bll K54 200R/BK* TORQUE CONVERTER CLUTCH SOLENOID CONTROL
B13 K28 18GY/LB INJECTOR NO. 8 DRIVER
B14 K116 18WT/DB INJECTOR NO. 10 DRIVER
B16 K14 18LB/BR INJECTOR NO. 4 DRIVER
B17 - -
B18 _
B19 _ -
B20 _ -
B22 ....
B23 - •
B24 ....

B26 _ -
B32 • -
* WITH AUTO TRANS

8050cd9c J968W-9
WHITE C 1 3 6 ( D I E S E L ENG)

Bll
B21
ooooooooooo
~\r\
oooooooooo VB12
Bl B2
B3
-
-
-
-
ooooooooooo
B32 B22 B4 - -
B5 -
B6 ....
-
POWERTRAIN _
CONTROL
B7 -
(CONNECTOR B) B9 -
Bll K54 200R/BK* TORQUE CONVERTER CLUTCH SOLENOID CONTROL
B12 - -
B13 --
B14 - -
B15 _ -
B16 - -
B17 -
B18 -
B19 - -
B20 G85 180R/BK WAIT-TO-START WARNING LAMP DRIVER
B22 -
B23 _ -
B24 - -
B26 - -
B32 - -
* WITH AUTO TRANS

8050cd9d J968W-9
BR 8W-80 CONNECTOR PiN-OUTS- 8W - 8 0 - 2 3
-GRAY C137 ( 3 . 9 L ENG)

Cl C13 20DB/0R A/C COMPRESSOR CLUTCH RELAY CONTROL
Cll ooooooooooo Cl C2 -
C21 oooooooooo C12 C3 K51 20DB/YL AUTO SHUT DOWN RELAY CONTROL
ooooooooooo
C32 C22 C4 V36 20TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
PJ C5 V35 20LG/RD SPEED CONTROL VENT SOLENOID CONTROL

C6 T18 20LG/0R* OVERDRIVE LAMP DRIVER
POWERTRAIN
C7 G14 18PK/BK* TRANSMISSION TEMPERATURE LAMP DRIVER
CONTROL
MODULE C8 - -
(CONNECTOR C) C9 - -
CIO - -
Cll V32 20YL/RD® SPEED CONTROL FEED
C12 A142 16DG/0R AUTO SHUT DOWN RELAY SENSE
C13 T6 20OR/WT TRANSMISSION OVERDRIVE SWITCH SENSE
C14 -
C15 K118 20PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
C16 G12 20TN/YL GEN LAMP DRIVER
C17 G3 20BK/PK MALFUNCTION INDICATOR LAMP DRIVER
C18 G24 20GY/PK SERVICE REMINDER INDICATOR LAMP DRIVER
C19 K31 20BR/WT FUEL PUMP RELAY CONTROL
C20 K52 20PK EVAPORATIVE EMISSION SOLENOID CONTROL
C21 -
C22 C20 18BR A/C REQUEST
C23 C90 18LG A/C SELECT INPUT
C24 V40 20WT/PK BRAKE SWITCH SENSE
C25
C26 K226 20DB/WT LOW FUEL SENSE
C27 D21 20PK/DB SCI TRANSMIT
C28 • -
C29 D20 20DG SCI RECEIVE
C30 - -
C31 G21 20GY/LB TACHOMETER SIGNAL
C32 V37 20RD/LG SPEED CONTROL SWITCH SIGNAL
• WITH SPEED CONTROL. H I G H - L I N E CLUSTER

* WITH AUTO TRANS
8050cd9e J968W-9
8W - 80 - 24 8W-80 CONNECTOR PIN-OUTS • 'BR
GRAY C 1 3 7 ( 5 . 2 L / 5 . 9 L ENG)

r Cl C13 20DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
Cll ooooooooooo Cl C2 - -
C21 oooooooooo C12 C3 K51 20DB/YL AUTO SHUT DOWN RELAY CONTROL
ooooooooooo ri
C32 C22 C4 V36 20TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
C5 V35 20LG/RD SPEED CONTROL VENT SOLENOID CONTROL
POWERTRAIN
C6 T18 20LG/OR* OVERDRIVE LAMP DRIVER
CONTROL C7 G14 1 8 P K / B K * TRANSMISSION TEMPERATURE LAMP DRIVER
MODULE C8 - _
(CONNECTOR C)
C9 -
CIO - -
Cll V32 2 0 Y L / R D * SPEED CONTROL FEED
C12 A142 16D6/0R AUTO SHUT DOWN RELAY SENSE
C13 T6 200R/WT TRANSMISSION OVERDRIVE SWITCH SENSE
C14 - -
C15 K118 20PK/YL BATTERY TEMPERATURE SENSOR SI6NAL
C18 624 20GY/PK SERVICE REMINDER INDICATOR LAMP DRIVER
C21 -
C25 - -
C28 - -
C30 - -
C31 G21 2 0 6 Y / L B TACHOMETER SIGNAL
C32 V37 20RD/L6 SPEED CONTROL SWITCH SIGNAL

* WITH AUTO TRANS
8050cd9f J968W-9
BR 8W-80 CONNECTOR PIN-OUTS- 8W - 80 - 25
GRAY C 1 . 3 7 ( 8 . 0 L ENG)

Cl C13 20DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
Cl C2 - -
en OOOOOOOOOOO
oooooooooo C12 C3 K51 20DB/YL AUTO SHUT DOWN RELAY CONTROL
C21
ooooooooooo
C22 C4 V36 20TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
C32
C5 V35 20LG/RD SPEED CONTROL VENT SOLENOID CONTROL
C6 T18 20LG/0R* OVERDRIVE LAMP DRIVER
POWERTRAIN
C7 G14 18PK/BK* TRANSMISSION TEMPERATURE LAMP DRIVER
CONTROL
MODULE C8 - -
(CONNECTOR C) C9 - -
CIO -
C12 A142 16DG/0R AUTO SHUT DOWN RELAY SENSE
C14 - -
C15 K118 20PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
C18 G24 20GY/PK SERVICE REMINDER INDICATOR LAMP DRIVER
C21 - -
C25 - -
C28 -
C30 - -

* WITH AUTO TRANS
8050cda0 J968W-9
- GRAY C137 ( D I E S E L ENG)

Cl C13 20DB/0R A/C COMPRESSOR CLUTCH RELAY CONTROL
Cll ooooooooooo Cl - -
C2
C21 oooooooooo C12
ooooooooooo C3 K51 20DB/YL AUTO SHUT DOWN RELAY CONTROL
C32 C22
C4 V36 20TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
IL C5 V35 20LG/RD SPEED CONTROL VENT SOLENOID CONTROL
POWERTRAIN C6 T18 20LG/0R* OVERDRIVE LAMP DRIVER

CONTROL C7 G14 18PK/BK* TRANSMISSION TEMPERATURE LAMP DRIVER
MODULE C8 -
(CONNECTOR C)
C9 D29 20PK/DG EGR DIAGNOSTIC
-
SIGNAL
CIO - -
C12 A142 16DG/OR AUTO SHUT DOWN RELAY SENSE
C14
C15 K118
-2 0 P K / Y L -
BATTERY TEMPERATURE SENSOR SIGNAL
C16 G12 2 0 T N / Y L GEN LAMP DRIVER
C18 G86 18TN/0R WATER-IN-FUEL WARNING LAMP DRIVER
C19 -
C20 -
C21 -
--
C25
C26
-- -
C27 D21 20PK/DB SCI TRANSMIT -
C28 -
C29 D20 20DG
- SCI RECEIVE
C30 -

* WITH AUTO TRANS
8050cdal J968W-9
BR 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 27
C138 (WITH GAS ENG)

2 K4 18BK/LB** SENSOR GROUND
2 K4 20BK/LB* SENSOR GROUND
3 K24 20GY/BK CRANK POSITION SENSOR SIGNAL
CRANKSHAFT
POSITION
SENSOR
BLACK
C13S (WITH DIESEL ENG)
2 K24 20GY/BK CRANK POSITION SENSOR SIGNAL
3 K4 20BK/LB SENSOR GROUND
ENGINE
SPEED
SENSOR
BLACK C139 (WITH GAS ENG)

1 G6 16GY OIL PRESSURE SENSE
2 G60 16GY/YL OIL PRESSURE SENSOR SIGNAL
ENGINE
OIL PRESSURE
SENSOR
€ 1 3 9 (WITH DIESEL ENG)

1 6618GY OIL PRESSURE SENSE
2 660 18GY/YL OIL PRESSURE SENSOR SIGNAL
* WITH 8.0L ENG

** WITH 3.9L. 5.2L AND 5.9L ENG
8050cda2 J968W-9
8W-80-28 - 8W-80 CONNECTOR PIN-OUTS BR
BLACK C140 (WITH 8 . 0 L ENG)

1 K116 18WT/DB INJECTOR NO. 10 DRIVER
2 A142 16DG/0R AUTO SHUT DOWN RELAY OUTPUT
INJECTOR NO. 10
BLACK
€141 (WITH 8 . 0 L ENG)

1 K17 18DB/WT I G N I T I O N COIL NO. 2 DRIVER
IGNITION COIL 2 A142 14DG/0R AUTO SHUT DOWN RELAY OUTPUT
4-PACK 3 K18 18RD/BK I G N I T I O N COIL NO. 3 DRIVER
BLACK €142
1 K28 1 8 G Y / L B * * INJECTOR NO. 8 DRIVER
1 K58 18BR/DB * INJECTOR NO. 6 DRIVER
INJECTOR NO. 8 ( V - 8 . V - 1 0 )
OR
INJECTOR NO. 6 ( V - 6 )
BLACK €143 (WITH 5 . 2 L . 5 . 9 L AND 8 . 0 L ENG)

1 K58 18BR/DB INJECTOR NO. 6 DRIVER
INJECTOR NO. 6 (V-8.V-10)
* WITH 3 . 9 L ENG
* * WITH 5 . 2 L . 5 . 9 L AND 8 . 0 L ENG
8050cda3 J968W-9
-BLACK C144 (WITH 8 . 0 L ENG)

1 K19 18BK/GY I G N I T I O N COIL NO. 1 DRIVER
2 K32 18YL/GY I G N I T I O N COIL NO. 4 DRIVER
4 K43 18DG/GY I G N I T I O N COIL NO. 5 DRIVER
IGNITION
COIL
6-PACK
-BLACK CMS
1 K14 18LB/BR INJECTOR NO. 4 DRIVER
INJECTOR NO. 4
BLACK C146 (WITH 5 . 2 L AND 5 . 9 L ENG)

2 F18 20LG/BK FUSED I G N I T I O N SWITCH OUTPUT (START/RUN)
EXHAUST
GAS RECIRCULATION
SOLENOID
C 1 4 6 (WITH DIESEL ENG)

BLACK C147

1 K12 18TN INJECTOR NO. 2 DRIVER
2 A142 16DG/OR AUTO SHUT DOWN RELAY OUTPUT
INJECTOR NO. 2
8050cda4 J968W-9
SW-11-31 -8W-80-CONNECTOR PIN-OUTS • -BR
BLACK C 1 4 8 (WITH 3 . 9 L , 5 . 2 L AND 5 . 9 L ENG)

2 Kl 18DG/RD MAP SENSOR SIGNAL
MANIFOLD
ABSOLUTE
PRESSURE
BLACK €148 (WITH 8 . 0 L ENG)

1 K4 1 8 B K / L B SENSOR GROUND
3 Kl 18DG/RD MAP SENSOR SIGNAL
MANIFOLD
ABSOLUTE
PRESSURE
BLACK €149 (WITH GAS ENG)

2 K22 180R/DB THROTTLE POSITION SENSOR
THROTTLE 3 K4 1 8 B K / L B SENSOR GROUND
POSITION
SENSOR
BLACK
€14? (WITH DIESEL ENG WITH AUTO TRANS OR EGR)

2 K22 200R/DB THROTTLE POSITION SENSOR SIGNAL
THROTTLE 3 K6 20VT/WT 5 VOLT SUPPLY
POSITION
SENSOR
8050cda5 J968W-9
BLACK C150

1 K39 18GY/RD I D L E AIR CONTROL MOTOR NO. 1 DRIVER
2 K60 18YL/BK I D L E AIR CONTROL MOTOR NO. 2 DRIVER
12 3 4 3 K40 18BR/WT I D L E AIR CONTROL MOTOR NO. 3 DRIVER
I D L E AIR 4 K59 18VT/BK I D L E AIR CONTROL MOTOR NO. 4 DRIVER

CONTROL MOTOR
BLACK
C1S1 (WITH GAS ENG)

o
1 K20 18DG GENERATOR F I E L D DRIVER
1 2 2 A142 14DB AUTO SHUT DOWN RELAY OUTPUT
GENERATOR 3 Zl 6BK GROUND
-BLACK C151 (WITH D I E S E L ENG)
J3) 4 CAV CIRCUIT FUNCTION

O
---B)0>3 1 K20 18DG GENERATOR F I E L D DRIVER
2 A142 14DB AUTO SHUT DOWN RELAY OUTPUT
3 All 6BK GENERATOR OUTPUT
1 2
4 Zl 6BK GROUND
GENERATOR
, — BLACK

2 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
COOLANT
TEMPERATURE
SENSOR
8050cda6 J968W-9
8W --80-32 8W-80 CONNECTOR PIN-OUTS • -BR
BLACK €153

1 K52 20PK EVAPORATIVE EMISSION SOLENOID CONTROL
2 F18 20LG/BK FUSED I G N I T I O N SWITCH OUTPUT
DUTY
CYCLE
EVAP/
PURGE
SOLENOID
C1S4 (WITH 8 . 0 L ENG)
BLACK
1 K115 18TN INJECTOR NO. 9 DRIVER
INJECTOR NO. 9
BLACK
C155

1 K26 1 8 V T / T N * * INJECTOR NO. 7 DRIVER
1 K38 18GY* INJECTOR NO. 5 DRIVER
INJECTOR NO. 7 ( V - 8 . V - 1 0 ) 2 A142 16DG/0R AUTO SHUT DOWN RELAY OUTPUT
OR
INJECTOR NO. 5 (V-6)
BLACK
C156 (WITH 5 . 2 L . 5 . 9 L AND 8 . 0 L ENG)

Hi CAV CIRCUIT FUNCTION
1 K38 18GY INJECTOR NO. 5 DRIVER
INJECTOR NO. 5 (V-8.V-10) 2 A142 16DG/0R AUTO SHUT DOWN RELAY OUTPUT
BLACK C157 (WITH GAS ENG)

A K4 18BK/LB SENSOR GROUND
B K21 18BK/RD INTAKE A I R TEMPERATURE SIGNAL
INTAKE A I R
TEMPERATURE
SENSOR
€15? (WITH DIESEL ENG)
A K4 16BK/LB SENSOR GROUND
B K21 16BK/RD INTAKE A I R TEMPERATURE SENSOR SIGNAL
* WITH 3 . 9 L ENG
* * WITH 5 . 2 L . 5 . 9 L AND 8 . 0 L ENG
8050cda7 J968W-9
8W-80 CONNECTOR PIN-OUTS 8W-80-33
1 y BLACK C1S8

1 K13 18YL/WT INJECTOR NO. 3 DRIVER
2 A142 16DG/OR AUTO SHUT DOWN RELAY OUTPUT
2
INJECTOR NO. 3
BLACK C159
1 Kll 18WT/DB INJECTOR NO. 1 DRIVER
INJECTOR NO. 1
•BLACK C l f O (WITH 5 . 9 L ENG HEAVY DUTY)

2 2 Z l l 18BK/WT GROUND
4 3 K4 1 8 B K / L B SENSOR GROUND
4 K41 18BK/DG UPSTREAM HEATED SENSOR SIGNAL
UPSTREAM HEATED
OXYGEN SENSOR
BLACK C161 (WITH MAN TRANS)

1 Ll 18VT/BK BACK-UP LAMP SWITCH OUTPUT
2 2 LIO 1 8 B R / L G FUSED IGNITION SWITCH OUTPUT (RUN)
BACK-UP
LAMP SWITCH
8050cda8 J968W-9
BLACK
OH (WITH 3 . 9 L . 5 . 2 L AND 5 . 9 L ENG EXCEPT HEAVY DUTY)

2 Zll 18BK/WT GROUND
4 K141 18TN/WT UPSTREAM HEATED OXYGEN SENSOR
UPSTREAM HEATED
OXYGEN SENSOR
-BLACK
C163

1 K7 180R 5 VOLT SUPPLY
3 G7 18WT/0R VEHICLE SPEED SENSOR SIGNAL
VEHICLE SPEED
SENSOR
BLACK
C164

1 C3 18DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT
A/C COMPRESSOR
CLUTCH
C165
BLACK
1 C90 18LG A/C PRESSURE SWITCH OUTPUT
2 C90 18LG/WT A/C PRESSURE SWITCH OUTPUT
A/C HIGH PRESSURE

CUTOUT SWITCH
8050cda9 J968W-9
BLACK C167
1 T16 18RD TRANSMISSION CONTROL RELAY OUTPUT
2 K7 180R 5 VOLT SUPPLY
4 T25 20LG/WT GOVERNOR PRESSURE SIGNAL
5 K88 20VT/WT VARIABLE FORCE SOLENOID CONTROL
TRANSMISSION
SOLENOID ASSEMBLY 6 T60 20BR OVERDRIVE SOLENOID CONTROL
7 K54 200R/BK TORQUE CONVERTER CLUTCH SOLENOID CONTROL
8 T54 18VT TRANSMISSION TEMPERATURE SENSOR SIGNAL
-BLACK
cira
1 K204 20BK/WT EGR IAT(-)
2 K321 20BK/PK EGR I A T ( + )
EGR INTAKE A I R
TEMPERATURE
SENSOR
BLACK
C1H9 (WITH AUTO TRANS)

1 LIO 18BR/LG FUSED I G N I T I O N SWITCH OUTPUT
2 T 4 1 18BK/WT PARK/NEUTRAL POSITION SWITCH SENSOR
PARK/NEUTRAL
POSITION SWITCH
BLACK C170 (WITH 3 . 9 L , 5.2L AND 5 . 9 L ENG)

1 K19 16BK/GY I G N I T I O N COIL NO. 1 DRIVER
IGNITION COIL
-BLACK
C171 ( I N DISTRIBUTOR WITH 3 . 9 L , 5.2L AND 5 . 9 L ENG)

3 2 1
3 K44 20TN/YL CAMSHAFT POSITION SENSOR SIGNAL
CAMSHAFT
POSITION
SENSOR
SOBOcdaa J968W-9
8W - 80-36' 8W-80 CONNECTOR PIN-OUTS< -BR
C172
1 A12 14RD/TN FUSED B( + )
2 F18 2 0 L 6 / B K FUSED I G N I T I O N SWITCH OUTPUT (START/RUN)
3
- -
4 A93 14RD/BK FUEL HEATER RELAY OUTPUT
FUEL HEATER 5 Z12 20BK/TN GROUND
RELAY
C173

1 A18 10RD/BK FUSED B( + )
2 T40 12BR ENGINE STARTER MOTOR RELAY OUTPUT
FUEL SHUT 4 A123 10RD/VT FUEL SHUT DOWN RELAY OUTPUT

DOWN RELAY
C174
BLACK
1 Kl 20DG/RD WATER-IN-FUEL SENSOR SIGNAL
WATER-IN-FUEL
SENSOR
£175

C B A
A F18 20LG/BK FUSED I G N I T I O N SWITCH OUTPUT (START/RUN)
B A123 10RD/VT FUEL SHUT DOWN RELAY OUTPUT
C Z12 10BK/TN GROUND
FUEL SHUT DOWN

SOLENOID
BLACK BLACK
C176
1 K304 20BK/LG 1 K304 20BK/LG
SQJI 2 K2 20TN/BK 2 K2 20TN/BK
2 1
8050cdab J968W-9
C177
BLACK
jim 1 A93 14RD/BK FUEL HEATER RELAY OUTPUT
umi2 2 Z12 16BK/TN GROUND
FUEL HEATER
BLACK BLACK
C178 (WITH DIESEL ENG)

HEATER INTAKE 2 S21 20YL/BK A I R INTAKE HEATER RELAY NO. 1 CONTROL
A I R SYSTEM
RELAY NO. 1
•BLACK BLACK
C 1 7 9 (WITH DIESEL ENG)

2 S22 200R/BK AIR INTAKE HEATER RELAY NO. 2 CONTROL
HEATER INTAKE
A I R SYSTEM
RELAY NO. 2
C180
POWER D I S T R I B U T I O N C E N T E R
(SEE 8W-11-3)
-BLACK
C181
OJ B
A T40 12BR STARTER RELAY OUTPUT
B AO 6RD B( + )
ENGINE STARTER
MOTOR
BLACK
C1S2
1 C20 18BR A/C SWITCH SENSE
A/C LOW PRESSURE 2 C90 18LG/WT A/C PRESSURE SWITCH OUTPUT
CUTOUT SWITCH
8050cdac J968W-9
SW --80-38 8W-80 CONNECTOR PIN-OUTS BR
C183
BLACK
CAV CIRCUIT
1 Ml 20PK
-OPTIONAL-
CHMSL JUMPER 2 M2 18YL
(FOR FUTURE USE) 3 L50 18WT/TN
4 Zl 20BK
•BLACK BLACK
C184
i to)
1 A58 6BK B(+)
INTAKE 2 A122 6BK B(+)
A I R HEATER
BLACK
C185 (WITH 3 . 9 L . 5 . 2 L AND 5 . 9 L ENG EXCEPT HEAVY DUTY)

DOWNSTREAM
HEATED OXYGEN 4 K341 180R/BK DOWNSTREAM HEATED OXYGEN SENSOR SIGNAL
SENSOR
BLACK C186 (WITH CALIFORNIA)

PRE-CATALYST HEATED
OXYGEN SENSOR 4 K441 18TN/RD PRE-CATALYST HEATED OXYGEN SENSOR SIGNAL
8050cdad J968W-9
BR 8W-80 CONNECTOR PIN-OUTS- 8W - 8 0 - 3 S
BLACK
CIS7
1 T14 18LG/BK OUTPUT SHAFT SPEED SENSOR SIGNAL
2 T13 18DB/BK OUTPUT SHAFT SPEED SENSOR GROUND
2 1
TRANSMISSION OUTPUT
SHAFT SPEED SENSOR
BLACK
C188
3 K242 20DG/LB FUEL PRESSURE SENSOR SIGNAL
FUEL PRESSURE
SENSOR
•BLACK C189
IMJ 2 K221 18TN/PK FUEL TEMPERATURE SENSOR SIGNAL
FUEL TEMPERATURE
SENSOR
BLACK
C190
2 1
LOW PRESSURE
FUEL SHUT OFF
SENSOR
BLACK
C191
2 K118 20PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
2 1
BATTERY
TEMPERATURE
SENSOR
8050cdae J968W-9
-80-40 8W-80 CONNECTOR PIN-OUTS BR
BLACK C192 (WITH 8 . 0 L ENG)

^ 2

4 K41 18BK/DG RIGHT UPSTREAM HEATED SENSOR SIGNAL
RIGHT UPSTREAM HEATED
OXYGEN SENSOR
r BLACK
CAV CIRCUIT
C193 (WITH 8 . 0 L ENG)
FUNCTION
2 2 Zll 18BK/WT GROUND
4 K141 18TN/WT LEFT UPSTREAM HEATED OXYGEN SENSOR SIGNAL
LEFT UPSTREAM HEATED
OXYGEN SENSOR
C 1 9 4 (WITH CALIFORNIA)
/—BLACK CAV CIRCUIT FUNCTION

l^Co\2 2 Zll 18BK/WT GROUND
4 K341 180R/BK POST CATALYST HEATED OXYGEN SENSOR SIGNAL
POST CATALYST HEATED
OXYGEN SENSOR
CI95 (WITH 5 . 9 L ENG HEAVY DUTY)

BLACK
4 K241 18BK/DG DOWNSTREAM HEATED OXYGEN SENSOR SIGNAL
DOWNSTREAM
HEATED OXYGEN
SENSOR
cdaf J968W-9
C201
BLACK
r BLACK
CAV
1 G16
CIRCUIT
22BK/LB
CAV
1 G16
CIRCUIT
18BK/LB
5 2 X13 18BK/RD 2 X13 18BK/RD
10 3 X53 18DG*
3 X53 20DG
3 X53 20DG"
4 Ml 20PK 4 Ml 20PK
5 P70 20WT 5 P70 20WT
6 M2 22YL 6 M2 18YL
7 12 18BK/LG 7 Z2 18BK/LG
8 X55 18BR/RD*
8 X55 20BR/RD
8 X55 20BR/RD"
9 P72 20YL/BK 9 P72 20YL/BK
10 P74 20DB 10 P74 20DB
C202
BLACK CAV CIRCUIT BLACK CAV CIRCUIT

1 F37 14RD/LB 1 F37 14RD/LB
P
Boi
2
3
X57
Ml
18BR/LB
18PK
2
3
X57
Ml
20BR/LB
18PK
4 Z2 18BK/LG 4 Z2 18BK/LG
] ••
5 X51 18BR/YL 5 X51 20BR/YL
6 M3 20PK/DB 6 M3 22PK/DB
7 X58 18DB/0R 7 X58 20DB/0R
m 12 8 M2 20YL 8 M2 20YL
m 9
10
11
G10
L50
X13
20LG/RD
18WT/TN
18BK/RD
9
10
11
G10 22LG/RD
L50
X13
18WT/TN
18BK/RD
12 X52 18DB/WT 12 X52 20DB/WT
C203
BLACK CIRCUIT FUNCTION
CAV
1 V32 22YL/RD SPEED CONTROL ON/OFF SWITCH SENSE
XL
- -
llnnn HO 2
VEHICLE SPEED 4 V37 22RD/LG SPEED CONTROL SWITCH SIGNAL
CONTROL/HORN 5 X3 2 0 B K / R D * HORN RELAY CONTROL
SWITCH
5 X3 2 2 B K / R D * * HORN RELAY CONTROL
• WITH PREMIUM SPEAKERS OR OPTIONAL

•• WITH STANDARD SPEAKERS
* WITHOUT POWER LOCKS AND POWER WINDOWS
** WITH POWER LOCKS AND POWER WINDOWS
8050cdb0 J968W-9
8W - 80 - 42 -8W-80 CONNECTOR PIN-OUTS 'BR
C204

1 1 M2 20YL COURTESY LAMPS DRIVER
2 2 Z3 20BK/OR GROUND
HEADLAMP
SWITCH
BLACK €2§§ •BLACK

1 R43 18BK/LB 1 R43 18BK/LB
2 R45 18DG/LB 2 R45 18DG/LB
C206

Bl A3 12RD/LG FUSED B( + )
BLACK
B2 F33 20PK/RD FUSED B( + )
B3 G26 18LB KEY-IN I G N I T I O N SWITCH SENSE
D M3 22PK/DB CARGO LAMP SWITCH GROUND
H L2 16LG HEADLAMP SWITCH OUTPUT
I El 20TN/0R PANEL LAMPS DIMMER SWITCH SIGNAL
P L20 16LG/WT FUSED B( + )
R L7 20BK/YL PARK LAMP SWITCH OUTPUT
U G16 22BK/LB LEFT FRONT DOOR JAMB SWITCH SENSE
HEADLAMP
SWITCH
_BLACK
BLACK
C207

1 4 1 F35 16RD 1 F35 14RD
5 8 2 F21 14TN 2 F21 14TN
3 Q16 14BR/WT 3 Q16 14BR/WT
4 Q26 14VT/WT 4 026 14VT/WT
5 P33 160R/BK 5 P33 160R/BK
6 P34 16PK/BK 6 P34 16PK/BK
7 P35 160R/VT 7 P35 1 6 0 R / V T
8 P36 16PK/VT 8 P36 16PK/VT
8050cdbl J968W-9
C208
1 E2 220R 1 E2 220R
2 F12 22DB/WT 2 F12 22DB/WT
BLACK
BLACK 3 L7 1 8 B K / Y L *
3 L7 20BK/YL
3 L7 2 0 B K / Y L * *
4 Ml 20PK 4 M l 20PK
1 5 5 M2 22YL°
5
as 5 M2 22YL*
6 10 6 Ll 22VT/BK
10 •DuDnEl 6 Ll 22VT/BK
7 LIO 22BR/LG 7 LIO 22BR/LG
8 G31 22VT/LG 8 G31 22VT/LG
9 G32 2 2 B K / L B 9 G32 22BK/LB
C209
1 E2 220R FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
6 -
7 - -
BLACK
12 F12 22DB/WT FUSED IGNITION SWITCH OUTPUT (START/RUN)
23
12
JXEixrnnrrj 33
22 15 F12 22DB/WT FUSED IGNITION SWITCH OUTPUT (START/RUN)
1 PL It3 11 16 - -
17 V32 20YL/RD SPEED CONTROL FEED
JOINT 18 V32 22YL/RD SPEED CONTROL FEED
CONNECTOR C
20 G16 2 2 B K / L B LEFT FRONT DOOR JAMB SWITCH SENSE
23 G9 22GY/BK RED BRAKE WARNING LAMP DRIVER
27 -
28 LIO 22BR/LG FUSED IGNITION SWITCH OUTPUT (RUN)
29 LIO 22BR/LG FUSED I G N I T I O N SWITCH OUTPUT (RUN)

* * WITH OVERHEAD CONSOLE ONLY
• WITH CONSOLE
8050cdb2 J968W-9
C210

10
1 V9 18WT/BK WIPER SWITCH MODE SIGNAL
D
• • n
18 2 V8 18VT WIPER SWITCH MODE SIGNAL
u
3 VIO 18BR WIPER SWITCH MODE SIGNAL
4 V6 16DB/BK FUSED I G N I T I O N SWITCH OUTPUT (ACC/RUN)
5 V4 16RD/YL WIPER SWITCH HIGH SPEED OUTPUT
6 V3 18BR/WT WIPER SWITCH LOW SPEED OUTPUT
• • 7 V7 18DG/WT WIPER PARK SWITCH SENSE
• • • 8 V17 18DG WIPER SWITCH DELAY OUTPUT
V3 18BR/WT WIPER SWITCH LOW SPEED OUTPUT
• • • 9
24 V3 18BR/WT WIPER SWITCH LOW SPEED OUTPUT
10
17
L60 20TN/BK RIGHT TURN SIGNAL
MULTI-FUNCTION 11
L60 18TN/BK RIGHT TURN SIGNAL
SWITCH
12 L62 18BR/PK RIGHT REAR TURN SIGNAL
13 L19 18PK/WT HAZARD FLASHER OUTPUT
14 L50 18WT/TN STOP LAMP SWITCH OUTPUT
15 L63 18DG/RD LEFT REAR TURN SIGNAL
L61 20LG/YL LEFT TURN SIGNAL
16
L61 18LG/YL LEFT TURN SIGNAL
17 L6 20RD/GY TURN SIGNAL FLASHER OUTPUT
18 L4 16VT/WT DIMMER SWITCH LOW BEAM OUTPUT
19 L2 16LG HEADLAMP SWITCH OUTPUT
20 L3 16RD/OR DIMMER SWITCH HIGH BEAM OUTPUT
21 L20 16LG/WT FUSED B( + )
22 -
23 - -
24 - -
C212

1 A41 18DB/YL I G N I T I O N SWITCH OUTPUT (START)
2 A21 12DB IGNITION SWITCH OUTPUT (START/RUN)
3 G9 22GY/BK RED BRAKE WARNING LAMP DRIVER (START)
7 1
IGNITION SWITCH 4 A2 12PK/BK FUSED B(+)
5 A22 12BK/0R IGNITION SWITCH OUTPUT (RUN)
6 A31 12BK/WT IGNITION SWITCH OUTPUT (ACC/RUN)
7 Al 12RD FUSED B(+)
8050cdb3 J968W-9
BLACK C213
•
• 1
2
G16
626
22BK/LB
18LB
LEFT FRONT DOOR JAMB SWITCH SENSE
KEY-IN I G N I T I O N SWITCH SENSE
• 3 Z3 20BK/0R GROUND
• 4 M50 22YL/RD KEY-IN LAMP DRIVER
KEY-IN-SWITCH/
HALO LAMP
€214
4 V30 20DB/RD SPEED CONTROL ON/OFF SWITCH OUTPUT
6 F32 18PK/DB FUSED B(+)
STOP LAMP
SWITCH
C215

2 - -
14 LUJ^JL 3 G21 22GY/LB TACHOMETER SIGNAL
4 66 22GY O I L PRESSURE SENSE
"ITU" 5
6
G12 22TN/YL
G3 22BK/PK
GEN LAMP DRIVER
MALFUNCTION INDICATOR LAMP DRIVER
INSTRUMENT
CLUSTER 7 G29 2 2 B K / T N * WASHER FLUID SWITCH SENSE
8 F14 20LG/YL FUSED I G N I T I O N SWITCH OUTPUT (START/RUN)
10 G60 22GY/YL O I L PRESSURE SENSOR SIGNAL
11 G4 22DB FUEL LEVEL SENSOR SIGNAL
12 _
13 G107 22BK/GY" 4WD LAMP

13 G107 20BK/GY* 4WD LAMP
• WITH RWAL
• • WITH ABS
* WITH SPEED CONTROL. H I G H - L I N E CLUSTER
8050cdb4 J968W-9
• BLACK C21S
n 1 G13 20DB/RD SEAT BELT LAMP DRIVER
1 4
I _ L U L T O I J :. ] 1
2 -
3 G54 220R/BK UPSHIFT LAMP DRIVER
or 4 G9 22GY/BK RED BRAKE WARNING LAMP DRIVER
INSTRUMENT
CLUSTER 5 Gil 22WT/BK PARK BRAKE SWITCH SENSE
7 G20 22VT/YL ENGINE COOLANT TEMPERATURE SENDING UNIT
8 - -
9 R41 18BK/TN AIRBAG SYSTEM WARNING LAMP DRIVER
10 Z3 20BK/OR GROUND
11 G7 20WT/0R VEHICLE SPEED SENSOR SIGNAL
12 L61 20LG/YL LEFT TURN SIGNAL
13 G34 18RD/GY HIGH BEAM INDICATOR LAMP DRIVER
14 L60 20TN/BK . RIGHT TURN SIGNAL
C217
BLACK
1 M2 20YL COURTESY LAMPS DRIVER
5
'T
-i
I -f
U
10
2
3
M2 22YL
M2 22YL
COURTESY LAMPS DRIVER
COURTESY LAMPS DRIVER
JOINT 4 L7 18BK/YL PARK LAMP SWITCH OUTPUT
CONNECTOR A 5 L7 20BK/YL PARK LAMP SWITCH OUTPUT
C218
BLACK
1 F12 20DB/WT FUSED I G N I T I O N SWITCH OUTPUT (START/RUN)
4
•••• 8
2
3
G13 20DB/RD
Z3 20BK/0R
SEAT BELT LAMP DRIVER
GROUND
4 G10 22LG/RD SEAT BELT SWITCH SENSE
BUZZER
MODULE
5 _ ....
G26 18LB KEY-IN I G N I T I O N SWITCH SENSE

6
G26 18LB KEY-IN I G N I T I O N SWITCH SENSE
7 Ml 20PK FUSED B ( + )
8 - -
8050cdb5 J968W-9
BLACK C219

1 V9 18WT/BK WIPER SWITCH MODE SIGNAL
VIO 18BR WIPER SWITCH MODE SIGNAL
2
INTERMITTENT WIPER VIO 18BR WIPER SWITCH MODE SIGNAL
CONTROL MODULE 3 V6 18DB/BK FUSED I G N I T I O N SWITCH OUTPUT (ACC/RUN)
4 V5 18DG/YL WIPER SWITCH MODE SENSE
5 Z3 18BK/0R GROUND
6 V7 18DG/WT WIPER PARK SWITCH SENSE
7 V17 18DG WIPER SWITCH DELAY OUTPUT
8 V8 18VT WIPER SWITCH MODE SIGNAL
C223
y BLACK, CAV CIRCUIT FUNCTION

]1 / _8[T^-L 1 _ -
2 - -
3 Dl 18VT/BR CCD BUS (+)
9 16
DATA LINK 5 Zll 20BK/WT GROUND
CONNECTOR 6 D20 20DG SCI RECEIVE
7 D21 20PK/DB SCI TRANSMIT
8 -
9 B113 20RD/VT RIGHT REAR WHEEL SPEED SENSOR (+)
10 - -
11 D2 18WT/BK CCD BUS (-)
12 Dll 22WT/RD SCI RECEIVE
13 B112 20BK RWAL SERVICE DIAGNOSTIC SIGNAL
14 - _
15 D12 220R SCI TRANSMIT

8050cdb6 J968W-9
BLACK C224

1 _ -
• ••• 2 G86 2 0 T N / O R * * WATER-IN-FUEL WARNING LAMP DRIVER
• ••• 3
4
F14 20LG/YL
G85 200R/BK**
FUSED I G N I T I O N SWITCH OUTPUT
WAIT-TO-START WARNING LAMP DRIVER
(START/RUN)
MESSAGE
CENTER 5 - -
6 - -
7 G24 22GY/PK SERVICE REMINDER INDICATOR LAMP DRIVER
8 G14 20PK/BK* TRANSMISSION TEMPERATURE LAMP DRIVER
C225
BLACK
1 T6 220R/WT TRANSMISSION OVERDRIVE SWITCH SENSE
2 Z3 20BK/OR GROUND
OVERDRIVE E2 200R FUSED PANEL LAMPS DIMMER SWITCH SENSE
SWITCH 4
E2 220R* FUSED PANEL LAMPS DIMMER SWITCH SENSE
T18 22LG/0R OVERDRIVE LAMP DRIVER
5 # #
G54 220R/BK UPSHIFT LAMP DRIVER
6 • -
GRAY C226

1 L35 22BR/WT FOG LAMP RELAY CONTROL
2 Z3 20BK/0R GROUND
FOG LAMP 3 Z3 20BK/0R GROUND
SWITCH
4 -
5 E2 220R FUSED PANEL LAMPS DIMMER SWITCH SENSE
6 L39 18LB FRONT FOG LAMP SWITCH OUTPUT
• WITH AUTO TRANS

NOT FUNCTIONAL WITH AUTO TRANS
* WITH FOG LAMPS
* * WITH DIESEL ENG
8050cdb7 J968W-9
BR 8W-80 CONNECTOR PIN-OUTS 8 W - 8 0 --49
BLACK C227
r rifirijns^^ C90 22LG*
2 A/C PRESSURE SWITCH OUTPUT
1 7
HEATER CONTROL 3 C5 16LG/YL Ml BLOWER MOTOR DRIVER
SWITCH 4 C4 16TN LO BLOWER MOTOR DRIVER
OR
5 C6 14LB M2 BLOWER MOTOR DRIVER
A/C-HEATER
CONTROL SWITCH 6 C7 12BK/TN HI BLOWER MOTOR DRIVER
7 Z3 12BK/OR GROUND
C228
1 B101 18LG/WT RWAL ISOLATION SOLENOID
ooooooo 7 A20 18RD/DB FUSED IGNITION SWITCH OUTPUT (RUN)
3
A20 18RD/DB* FUSED IGNITION SWITCH OUTPUT (RUN)
o o o o o o o 14
G107 20BK/GY 4WD SENSE
CONTROLLER 4
G107 20BK/GY 4WD SENSE
ANTI-LOCK
BRAKE 5 G i l 22WT/BK PARK BRAKE SWITCH SENSE
(RWAL) 6 G9 22GY/BK RED BRAKE WARNING LAMP DRIVER
8 B108 18WT RWAL DUMP SOLENOID
9 F32 20PK/DB FUSED B( + )
10 Z3 16BK/0R GROUND
11 B i l l 22LB/BK RWAL RESET SWITCH
12 B112 20BK RWAL SERVICE DIAGNOSTIC SIGNAL
13 B114 22WT/VT RIGHT REAR WHEEL SPEED SENSOR (-)
B113 20RD/VT RIGHT REAR WHEEL SPEED SENSOR ( + )
14
B113 20RD/VT RIGHT REAR WHEEL SPEED SENSOR (+)
C229
GRAY
1 - -
••••••• 2 X55 20BR/RD LEFT FRONT DOOR SPEAKER (-)
1
Ll 3 X56 20DB/RD RIGHT FRONT DOOR SPEAKER (-)
RADIO 4 L7 20BK/YL PARK LAMP SWITCH OUTPUT
6 X12 18RD/WT FUSED IGNITION SWITCH OUTPUT (ACC/RUN)
7 Ml 20PK FUSED B(+)
• WITH A/C ONLY

* WITH DIESEL ENG
8050cdb8 J968W-9
BLACK C230
n
••••••• 1 X60 22DG/RD* RADIO 12 VOLT OUTPUT
1 LT 7 2 X51 20BR/YL LEFT REAR SPEAKER ( + )
RADIO 3 X52 20DB/WT RIGHT REAR SPEAKER (+)
4 X53 20DG LEFT FRONT DOOR SPEAKER (+)
5 X54 20VT RIGHT FRONT DOOR SPEAKER ( + )
6 X57 20BR/LB LEFT REAR SPEAKER (-)
7 X58 20DB/0R RIGHT REAR SPEAKER ( - )
C231
j— BLACK CAV CIRCUIT FUNCTION

5 1 Ml 20PK FUSED B( + )
-E 10
2
3
Ml 20PK
--
FUSED B(+)
JOINT 4 F32 18PK/DB FUSED B( + )

-
CONNECTOR B 5 F32 18PK/DB FUSED B( + )
9 F32 20PK/DB FUSED B( + )
....
10 -
C232

6 1 1 F14 18LG/YL FUSED I G N I T I O N SWITCH OUTPUT (START/RUN)
2 F23 18DB/YL FUSED I G N I T I O N SWITCH OUTPUT (RUN)
3 Dl 18VT/BR CCD BUS (+)
4 D2 18WT/BK CCD BUS (-)
13 7
5 R49 18LB LEFT IMPACT SENSOR LINE 2
AIRBAG
6 R47 18DB/LB LEFT IMPACT SENSOR LINE 1
CONTROL MODULE
7 R41 18BK/TN AIRBAG SYSTEM WARNING LAMP DRIVER
8 - -
9 - -
10 -
11 Z6 18BK/0R GROUND
-
12 R48 18TN RIGHT IMPACT SENSOR LINE 2
13 R46 18BR/LB RIGHT IMPACT SENSOR LINE 1
* WITH PREMIUM RADIO

8050cdb9 J968W-9
BLACK C233

• 1 _
n
AIRBAG CONTROL 2 - --
MODULE 3 R43 18BK/LB AIRBAG LINE 1
4 R45 18DG/LB AIRBAG LINE 2
C234
BLACK
2 X13 18BK/RD PREMIUM SPEAKER AMPLIFIER
3 X60 22DG/RD RADIO 12 VOLT OUTPUT
4 Z2 18BK/LG GROUND
RADIO
CHOKE
RELAY
C235
BLACK
1 F130 18RD/YL FUSED I G N I T I O N SWITCH OUTPUT (ACC/RUN)
2 Z3 18BK/0R GROUND
POWER
OUTLET
-BLACK
C236
A F30 18RD/0R FUSED I G N I T I O N SWITCH OUTPUT (ACC/RUN)
B Z3 18BK/0R GROUND
CIGAR
LIGHTER
-BLACK C237 BLACK

1_ 1 C7 12BK/TN 1 C7 12BK/TN
1 2 C6 14LB 2 C6 14LB
3 C5 16LG 3 C5 16LG/YL
3
4 C4 16TN 4 C4 16TN
8050cdba J968W-9
-8W-80 CONNECTOR PIN-OOTS • -BR
8W -m* 12
BLACK C238

1 C l 12DG FUSED I G N I T I O N SWITCH OUTPUT (RUN)
2 C7 12BK/TN H I BLOWER MOTOR DRIVER
BLOWER
MOTOR
C239
• BLACK BLACK
1 1 -
2 - 2 -
3 F21 14TN 3 F21 14TN
4 016 14BR/WT 4 Q16 14BR/WT
5 Q26 14VT/WT 5 Q26 14VT/WT
6 P36 16PK/VT 6 P36 16PK/VT
7 F35 16RD 7 F35 16RD
8 P33 160R/BK 8 P33 160R/BK
9 P34 16PK/BK 9 P34 16PK/BK
10 P35 160R/BT 10 P35 160R/VT
C240
BLACK BLACK
1 X13 18BK/RD 1 X13 18BK/RD
1 X54 2 0 V T * *
2 X54 20VT 2
X54 18VT*
5
3 P70 20WT 3 P70 20WT
4 P72 20YL/BK 4 P72 20YL/BK
5 Z2 18BK/LG 5 Z2 18BK/LG
6 X56 18DB/RD*
6 X56 20DB/RD
6 X56 2 0 D B / R D * *
7 M2 22YL 7 M2 18YL
8 P74 20DB 8 P74 20DB
C241
FiSE B L O C St "
(SEE 8W-10-3)
* WITH PREMIUM SPEAKERS OR OPTIONAL

** WITH STANDARD SPEAKERS
8050cdbb J968W-9
8W-80 CONNECIOi PIN-OMTS- 8W - 80 - 58
BLACK €301
1
1 12 18BK/LG GROUND
RIGHT REAR 2 X58 18DB/0R RIGHT REAR SPEAKER (-)
PREMIUM SPEAKER 3 X52 18DB/WT RIGHT REAR SPEAKER ( + )
BLACK C302

CD B
A X58 18DB/0R RIGHT REAR SPEAKER (-)
RIGHT REAR B X52 18DB/WT RIGHT REAR SPEAKER ( + )
SPEAKER
€303
-BLACK CAV CIRCUIT -BLACK CAV CIRCUIT
1 Z3 14BK/0R 1 Z3 14BK/0R
2 F37 14RD/L3 2 F37 14RD/LB
D <0
C304
BLACK
f CAV CIRCUIT FUNCTION
DOME
LAMP
C305
BLACK
1 Z2 18BK/LG GROUND
1
2 X57 18BR/LB LEFT REAR SPEAKER (-)
LEFT REAR 3 X51 18BR/YL LEFT REAR SPEAKER (+)
PREMIUM SPEAKER 4 X13 18BK/RD PREMIUM SPEAKER AMPLIFIER
J968W-9
8W - 80 - 54 •8W-80 CONNECTOR PIN-OUTS BR
BLACK C306
A X57 18BR/LB LEFT REAR SPEAKER (-)
LEFT REAR B X51 18BR/YL LEFT REAR SPEAKER (+)

SPEAKER
€307
BLACK
1 G10 20LG/RD SEAT BELT WARNING SWITCH SENSE
13 18BK/0R GROUND
2
13 18BK/0R GROUND
SEAT BELT
SWITCH
€30©
BLACK CAV CIRCUIT CAV CIRCUIT

BLACK
L50 18WT/TN
1 1 L50 18WT/TN
L50 18WT/TN 3
13 18BK/0R
2 6 2 Z3 18BK/0R
Z3 18BK/0R
Ml 18PK*
3 3 Ml 18PK
Ml 18PK*
M3 1 8 P K / D B *
4 4 M3 20PK/DB
M3 1 8 P K / D B *
5 - 5
6 6 -
€309
BLACK
1 Z3 18BK/0R® GROUND
1 Z3 20BK/0R®® GROUND
LEFT DOOR 3 G16 18BK/LB DOOR JAMB SWITCH SENSE
JAMB SWITCH
C310

1 P74 20DB POWER MIRROR LEFT CONTROL
L i . .. . 2 P72 20YL/BK POWER MIRROR UP CONTROL

3 P70 20WT POWER MIRROR RIGHT/DOWN CONTROL
bi_rurJ j
r- 4 Ml 20PK FUSED B(+)
5 P75 20DB/WT POWER MIRROR UP CONTROL
POWER
6 P71 20YL POWER MIRROR LEFT CONTROL
MIRROR
SWITCH 7 P73 20YL/PK POWER MIRROR RIGHT/DOWN CONTROL
8 Z3 18BK/0R GROUND
• WITH OPTIONAL
m e
WITHOUT OPTIONAL
* WITH CARGO LAMPS
8050cdbd J968W-9
Dn 8W-80 CONNECTOR PIN-OUTS 8W - 8 0 - 5 5
BLACK C311

1 P75 20DB/WT POWER MIRROR UP CONTROL
2 P73 20YL/PK POWER MIRROR RIGHT/DOWN CONTROL
LEFT POWER 3 P71 20YL POWER MIRROR LEFT CONTROL
MIRROR MOTORS
BLACK
C312

A X55 20BR/RD LEFT DOOR SPEAKER (-)
B X53 20DG LEFT DOOR SPEAKER (+)
LEFT DOOR
SPEAKER
^r-— BLALi

1 Z2 18BK/LG GROUND
1 (flWlP^ 4 2 X55 18BR/RD LEFT DOOR SPEAKER (-)
3 X53 18DG LEFT DOOR SPEAKER (+)
PREMIUM
SPEAKER
-BLACK C314 (PREMIUM)

1 X55 18BR/RD LEFT DOOR SPEAKER (-)
2 X53 18DG LEFT DOOR SPEAKER (+)
LEFT DOOR
TWEETER
-BLACK C315
4
1 P35 160R/VT DOOR LOCK SWITCH OUTPUT (LOCK)
2 Z3 14BK/0R GROUND
3 5 3 F35 14RD FUSED B( + )

LEFT POWER 4 Z3 14BK/0R GROUND
DOOR LOCK 5 P36 16PK/VT DOOR LOCK SWITCH OUTPUT (UNLOCK)
SWITCH
8050cdbe J968W-9
- BLACK C31S
4 ~
r~
3
2 1 Qll 14LB POWER WINDOW UP CONTROL
6 o
o o 2 Q21 14WT POWER WINDOW DOWN CONTROL
5 o o3 o 1 3 Z3 14BK/0R GROUND
4 F21 14TN FUSED I G N I T I O N SWITCH OUTPUT (RUN)
LEFT POWER 5 Q16 14BR/WT POWER WINDOW SWITCH OUTPUT (UP)
WINDOW SWITCH 6 026 14VT/WT POWER WINDOW SWITCH OUTPUT (DOWN)
BLACK C317

1 P34 16PK/BK DOOR UNLOCK DRIVER
2 P33 160R/BK DOOR LOCK DRIVER
LEFT POWER
DOOR LOCK
MOTOR
BLACK
C318

1 Qll 14LB POWER WINDOW UP CONTROL
2 Q21 14WT POWER WINDOW DOWN CONTROL
LEFT POWER
WINDOW MOTOR
C319
BLACK
1 Z3 18BK/0R GROUND
RIGHT DOOR
JAMB SWITCH
C32§
BLACK
A X56 20DB/RD RIGHT DOOR SPEAKER (-)
B X54 20VT RIGHT DOOR SPEAKER (+)
RIGHT DOOR
SPEAKER
8050cdbf J968W-9
-BLACK
C321

1 012 14BR POWER WINDOW UP CONTROL
2 Q22 14VT POWER WINDOW DOWN CONTROL
RIGHT POWER
WINDOW MOTOR
C322
BLACK
1 2 3 / CAV CIRCUIT FUNCTION
1 P74 20DB POWER MIRROR LEFT CONTROL
2 P70 20WT POWER MIRROR RIGHT/DOWN CONTROL
3 P72 20YL/BK POWER MIRROR UP CONTROL
RIGHT
POWER MIRROR
MOTORS
C323

1 Z2 18BK/LG GROUND
2 X56 18DB/RD RIGHT DOOR SPEAKER (-)
3 X54 18VT RIGHT DOOR SPEAKER (+)
RIGHT DOOR
PREMIUM SPEAKER
C324 (PREMIUM)
-BLACK
1 X56 18DB/RD RIGHT DOOR SPEAKER (-)
2 X54 18VT RIGHT DOOR SPEAKER (+)
RIGHT DOOR
TWEETER
C325

2 P36 16PK/VT DOOR LOCK SWITCH OUTPUT (UNLOCK)
3 5 3 F35 16RD FUSED B ( + )
4 P35 160R/VT DOOR LOCK SWITCH OUTPUT (LOCK)
RIGHT POWER
DOOR LOCK SWITCH
8050cdc0 J968W-9
8W - 80 - 58 8W-80 CONNECTOR PIN-OUTS' 'BR
C326

1 022 14VT POWER WINDOW DOWN CONTROL
2 Q16 14BR/WT POWER WINDOW SWITCH OUTPUT (UP)
3 F21 14TN FUSED I G N I T I O N SWITCH OUTPUT
4 026 14VT/WT POWER WINDOW SWITCH OUTPUT (DOWN)
3 5 5 012 14BR POWER WINDOW UP CONTROL
RIGHT POWER
WINDOW SWITCH
BLACK S327
RIGHT POWER
DOOR LOCK
MOTOR
C328
BLACK
1 A61 16DG/BK* AUTO SHUT DOWN RELAY OUTPUT
2 K104 20DB/WT* FUSED B( + )
1 3 G4 20DB/0R FUEL LEVEL SENSOR SIGNAL
cm czi •
CZJ cm cz3 4 Zll 20BK/WT GROUND
4
5 K4 2 0 B K / L B * SENSOR GROUND
FUEL PUMP
MODULE 6 Z13 16BK* GROUND
BLACK C329 BLACK

1 L7 18BK/YL 1 L7 18BK/YL
2 Z13 18BK 2 Z13 18BK
3 L62 18DG/BR 3 L62 18BR/PK
4 Ll 18VT/BK 4 Ll 18VT/8K
€330 BLACK
BLACK
1 B113 20RD/VT 1 B113 20RD/VT
2 B114 20WT/VT 2 B114 20WT/VT
* NOT FUNCTIONAL ON DIESEL

SOSOedcl J968W-9
8W-80 CONNECTOR PIN-iiuYS- 8W - 80 - II
— BLACK €331 BLACK

1 L l 16VT/BK 1 Ll 18VT/BK
2 L62 18BR/PK 2 L62 18BR/PK
3 L63 18DG/RD 1 2 3 3 L63 18DG/RD
3 2 1
€332
/—BLACK
CAV CIRCUIT BLACK CAV CIRCUIT
1 A6 14RD/TN 1 A6 14RD/TN
2 B40 14LB 2 B40 14LB
3 Z13 12BK 3 Z13 12BK
4 L76 12BK/OR 4 L76 12BK/0R
€333
2 Z13 18BK 2 Z13 18BK
3 L63 18DG/BR 3 L63 18DG/RD
€334
BLACK
2 Z4 22BK GROUND
DAY/NIGHT
MIRROR
BLACK
€335
rCAV CIRCUIT FUNCTION

L
L7 18BK/YL PARK LAMP SWITCH OUTPUT
Ii i
Z4 18BK GROUND
\LL_iV I 2
2 1
LEFT OUTBOARD
CLEARANCE LAMP
cdc2 J968W-9
8W - 81 - 1 6 8W-80 CONNECTOR PIN-0UT8 •
BLACK
C33§
2 14 18BK GROUND
2 1
LEFT OUTBOARD
IDENTIFICATION
LAMP
C 3 3 7 (WITH LOW-LINE CLUSTER)

1 Z4 18BK GROUND
OVERHEAD
MAP/COURTESY
LAMP
C33S (WITH H I G H - L I N E CLUSTER)

BLACK
8 • • • • • • 13 1 E2 220R FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
cn a o a • •
1 ( • • • • • • • 117 2 L7 2 0 B K / Y L * * PARK LAMP SWITCH OUTPUT

• • • • • • • 2 L7 18BK/YL* PARK LAMP SWITCH OUTPUT
OVERHEAD 3 - -
CONSOLE 4 G32 2 2 B K / L B SENSOR GROUND
5 G31 2 2 V T / L G AMBIENT TEMPERATURE SENSOR SIGNAL
8 -
10 - -
11 Z4 18BK GROUND
12 Ml 18PK FUSED B(+>
-BLACK
C339
/ 2 Z4 18BK GROUND
j
2 1
CENTER
IDENTIFICATION
LAMP

* * WITH OVERHEAD CONSOLE ONLY
8050cdc3 J968W-9
8W-80 CONNECTOR PIN-OUTS 8W - 80 - 61
BLACK
C34§
1 PARK LAMP SWITCH OUTPUT
2 17 18BK
Z4 18BK/YL GROUND
2 1
RIGHT OUTBOARD
IDENTIFICATION
LAMP
BLACK
C341

2 Z4 18BK GROUND
RIGHT OUTBOARD
CLEARANCE
LAMP
BLACK BLACK
€342
1 Z13 18BK 1 Z13 18BK
BLACK C343 BLACK

1 Z13 18BK 1 Z13 18BK
J968W-9
8W-88 -12 8W-80 CONNECTOR FIN-OUTS BR
• BLACK C345 BLACK
2 1 - 1 -
6 2 X54 18VT*
12
2 X54 18VT
2 X54 20VT M
3 P70 20WT 3 P70 20WT

4 P72 2 0 Y L / B K 4 P72 2 0 Y L / B K
5 X56 18DB/RD®
5 X56 18DB/RD ##
5 X56 20DB/RD
6 X13 18BK/RD 6 X13 18BK/RD
7 P74 20DB 7 P74 20DB
8 - 8 -
9 F21 14TN 9 F21 14TN
10 - 10 -
11 Z2 1 8 B K / L G 11 Z2 1 8 B K / L G
C346 BLACK
-BLACK
1 F35 16RD 1 F35 16RD
4 o
2 Q16 14BR/WT 4 2 Q16 14BR/WT
10 DD 10
3 Q26 14VT/WT 3 Q26 14VT/WT
4 P33 160R/BK 4 P33 160R/BK
5 P34 16PK/BK 5 P34 16PK/BK
6 P35 160R/VT 6 P35 160R/VT
7 P36 16PK/VT 7 P36 16PK/VT
C34?
BLACK BLACK
1 Ml 20PK 1 Ml 20PK
X53 18DG*
2 X53 18DG 2
X53 20DG"
3 P70 20WT 3 P70 20WT
4 P72 2 0 Y L / B K 4 P72 2 0 Y L / B K
#
X55 18BR/RD
5 X55 18BR/RD 5
X55 20BR/RD"
6 X13 18BK/RD 6 X13 18BK/RD
7 P74 20DB 7 P74 20DB
9 F21 14TN 9 F21 14TN
10 Z3 14BK/0R* 10 Z3 14BK/0R*
10 Z3 18BK/0R** 10 Z3 18BK/0R**
11 Z2 1 8 B K / L G 11 Z2 1 8 B K / L G
• WITH PREMIUM SPEAKERS

WITH STANDARD SPEAKERS
* WITH POWER WINDOWS AND POWER LOCKS
** WITHOUT POWER WINDOWS AND POWER LOCKS
8050cdc5 J968W-9
mm 8W-80 CONNECTOR PIN-OUH 8W-80 -63
C348
• BLACK BLACK
1 F35 14RD 1 F35 14RD
4 2 Q16 14BR/WT 2 016 14BR/WT
10 DD 3 Q26 14VT/WT 4 3 026 14VT/WT
TT TT TT 17 TT T? 10
4 P33 160R/BK 4 P33 160R/BK
5 P34 16PK/BK 5 P34 16PK/BK
6 P35 160R/VT 6 P35 160R/VT
7 P36 16PK/VT 7 P36 16PK/VT
BLACK
C352 BLACK
n 1 Ml 20PK
1 Ml 20PK
CrD 2 Z4 20BK
1 2 2 Z4 20BK
2 1
BLACK
C353 BLACK
X L
1 Ml 20PK 1 Ml 20PK
1 2 2 Z4 20BK 2 Z4 20BK
2 1
- BLACK C401
1 C7 12BK/TN HI BLOWER MOTOR DRIVER
2
2 C6 14LB M2 BLOWER MOTOR DRIVER
3 3 C5 16LG MI BLOWER MOTOR DRIVER
BLOWER MOTOR 4 C4 16TN LO BLOWER MOTOR DRIVER
RESISTOR
BLOCK
8050cdc6 J968W-9
8W - 80 - 64 -8W-80 CONNECTOR PIN-OUTS BR
BLACK - BLACK
C402
2 Z13 18BK 2 Z13 18BK
BLACK BLACK
C40S
1
1 L7 18BK/YL 1 L7 1 8 B K / Y L
ZED 2 2 Z13 18BK 2 ZI3 18BK
BLACK C404 BLACK

1 L7 1 8 B K / Y L 1 L7 1 8 B K / Y L
ZHD 2 2 Z13 18BK 2 Z13 18BK
BLACK C405 BLACK

ZHD 2
1 L7 1 8 B K / Y L nnz 1 L7 1 8 B K / Y L
2 Z13 18BK 2 Z13 18BK
BLACK BLACK
C406
1 Z13 18BK 1 Z13 18BK
2 L7 1 8 B K / Y L 2 L7 1 8 B K / Y L
8050cdc7 J968W-9
BLACK C407
1 6107 18BK/GY 4WD SENSE

2 Zl 18BK GROUND
4WD SWITCH
BLACK C409
1 B114 20WT/VT RIGHT REAR WHEEL SPEED SENSOR(-)
2 B113 20RD/VT RIGHT REAR WHEEL SPEED SENSOR(+)
REAR WHEEL
SPEED SENSOR
BLACK
C410
2 M3 18PK/DB CARGO LAMP SWITCH GROUND
il
CARGO
LAMP NO. 1
BLACK
C411
1 Ml 18PK FUSED B(+)
2 M3 18PK/DB CARGO LAMP SWITCH GROUND
11
CARGO
LAMP NO. 2
8050cdc8 J968W-9
8W - 80 - §6 -8W-80 CONNECTOR PIN-OUTS • mm
BLACK
C412

2 GROUND
13 18BK/0R
CENTER HIGH
MOUNTED STOP
LAMP NO. 1
BLACK
C413

2 GROUND
13 18BK/0R
CENTER HIGH
MOUNTED STOP
LAMP NO. 2
BLACK C414
1 L7 1 8 B K / Y L PARK LAMP SWITCH OUTPUT
2 Z13 18BK GROUND
RIGHT
LICENSE
LAMP
1 2 3 C415
-BLACK
O
°°1 CAV
i Z13
CIRCUIT
18BK GROUND
FUNCTION
2 L7 1 8 B K / Y L PARK LAMP SWITCH OUTPUT

3 L62 18DG/BR RIGHT REAR TURN SIGNAL
RIGHT T A I L . STOP AND
TURN SIGNAL LAMP
C41S
GRAY
o o
1 Z13 18BK GROUND
p i a
RIGHT
BACK-UP LAMP
8050cdc9 J968W-9
BR • 8W-80 CONNECTOR PIN-OUTS- 8W - 80 - §7
BLACK C417
2 Z13 18BK GROUND
LEFT
LICENSE
LAMP
3 2 1 C418
BLACK
O O Q | ^ / ~ " CAV CIRCUIT FUNCTION
1 Z13 18BK GROUND
3 L63 18DG/BR LEFT REAR TURN SIGNAL
LEFT T A I L . STOP AND
TURN SIGNAL LAMP
C419
GRAY
1 Z13 18BK GROUND
a g
LEFT BACK-UP
LAMP
BLACK
C420 (DUAL REAR WHEELS)

1 Z13 18BK GROUND
1 2
LEFT FORWARD
FENDER LAMP
-BLACK

1 Z13 18BK GROUND
RIGHT FORWARD
FENDER LAMP
8050cdca J968W-9
8W - 80 - 68 -8W-80 CONNECTOR PIN-OUTS BR
BLACK
1 Z13 18BK GROUND
1 2
LEFT REAR
FENDER LAMP
BLACK

1 Z13 18BK GROUND
1 2
RIGHT REAR
FENDER LAMP
BLACK

1 Z13 18BK GROUND
1 2
LEFT
TAILGATE
LAMP
BLACK

1 Z13 18BK GROUND
1 2 2 L7 18BK/YL PARK LAMP SWITCH OUTPUT

RIGHT
TAILGATE
LAMP

BLACK
2 „1
2 Z13 18BK GROUND
LEFT
LICENSE
LAMP
8050cdcb J968W-9
BLACK C427
1 Z13 12BK GROUND
2 B40 14LB TRAILER TOW ELECTRIC BRAKE OUTPUT
3 L76 12BK/0R TRAILER TOW RELAY OUTPUT
4 A6 12RD/TN FUSED B ( + )
5 L63 18D6/RD LEFT REAR TURN SIGNAL
TRAILER
TOW CONNECTOR 6 L62 18BR/PK RIGHT REAR TURN SIGNAL
r BLACK
C428

1 P15 1 4 Y L / L B POWER SEAT HORIZONTAL FORWARD
2 P17 14DB/RD POWER SEAT HORIZONTAL BACKWARD
FORWARD/BACKWARD
SEAT MOTOR
RED C429

1 P13 14RD/WT POWER SEAT REAR DOWN
2 Pll 14YL/WT POWER SEAT REAR UP
REAR/VERTICAL
SEAT MOTOR
RED C430
1 P21 14RD/LG POWER SEAT FRONT DOWN
2 P19 14YL/LG POWER SEAT FRONT UP
FRONT UP/DOWN
SEAT MOTOR
8050cdcc J968W-9
8W - 80 - 70 •8W-80 CONNECTOR PIN-OUTS • BR
C431
BLACK
1 - -
2 Pll 14YL/WT POWER SEAT REAR UP
3 F37 14RD/LB FUSED B( + )
i 7 4 P17 14DB/RD POWER SEAT HORIZONTAL BACKWARD
8p 9( c £l 10 ft ^ 5 Z3 14BK/0R GROUND
6 P19 14YL/LG POWER SEAT FRONT UP
POWER SEAT SWITCH 7 - -
8 - -
9 - -
10 P13 14RD/WT POWER SEAT REAR DOWN
11 P15 14YL/LB POWER SEAT HORIZONTAL FORWARD
12 P21 14RD/LG POWER SEAT FRONT DOWN
BLACK €432
1 Zl 20BK GROUND
2
O 2 L39 20LB FRONT FOG LAMP SWITCH OUTPUT
RIGHT FOG
LAMP
BLACK C433
1 Zl 20BK GROUND
2(t 2 L39 20LB FRONT FOG LAMP SWITCH OUTPUT
LEFT FOG
LAMP
BLACK C434
1 K304 20BK/LG EGR COOLANT TEMPERATURE SENSOR SIGNAL
2 K2 20TN/BK EGR ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
EGR
ENGINE COOLANT
TEMPERATURE SENSOR
8050cdcd J968W-9
BLACK
C435
A Ml 2QPK FUSED B(+)
O L Z Z B Z4 20BK GROUND
B
LEFT VISOR/VANITY
LAMP
BLACK
C436
r
f A Ml 20PK FUSED B(+)
) B Z4 20BK GROUND
RIGHT VISOR/VANITY
LAMP
8050cdce J968W-9
BR 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 1
8W-90 CONNECTOR/GROUND LOCATIONS
INTRODUCTION CONNECTOR/GROUND LOCATIONS

This section provides illustrations identifying com For items that are not shown in this section, N/S is
ponent and connector locations in the vehicle. A con placed in the Fig. column.
nector index is provided. Use the wiring diagrams in
each section for connector number identification.
Refer to the index for the proper figure number.
Conn # Color Location Fig. Conn # Color Location Fig.

C101 BK At Lamp 1 C129 BK Above Left Front Body 2, 20
C102 BL At Headlamps 1 Cushion
C103 BK Right Fender Side Shield 1 C130 BK At Underhood Lamp 4

C104 GN Right Fender Side Shield 1 C131 BK Left Fender Side Shield 2
C105 BK Rear of Front Bumper 5 C132 GN Top of Clutch Pedal N/S

C106 BK On Front Axle 23 C133 BK Bottom of I.R, Near 12
Steering Column
C107 BK Bottom of Washer Bottle 2
C134 BK Left Fender Side Shield 4
C108 BK Side of Washer Bottle 2
C135 BK At PCM 3
C109 BK Below Battery 4
C136 WT At PCM 3
C137 GY At PCM 3
cm BK At EGR Control Module N/S
C138 BK Rear of Engine Block (V-6, 6, 7
C112 BK At Lamp 2
V-8)
C113 BL At Headlamp 2
C138 BK Right Side of Engine Block 8
C114 BK Radiator Left Support 4 (V-10)
C115 BK Front Bumper Left Support 2 C138 BK Front of Engine (Diesel) 9
C116 BK Front Bumper Left Support 2 C139 BK Near Distributor (V-6, V-8) 6,7
C117 BK Below Brake Master 3 C139 BK Near Oil Filter (V-10) 8
Cylinder
C139 BK Left Side of Engine (Diesel) 9
C140 BK Injector No. 10 8
C119 BK Below PDC 3
C141 BK Right Side of Engine 8
C120 BK At Controller Antilock 3
C142 BK Injector No. 8 7, 8
Brakes
C143 BK Injector No. 6 6, 7, 8
C121 BK At Controller Antilock 3
Brakes C144 BK Right Side of Engine 8
C122 BK Rear of ABS Pump 3 C145 BK Injector No. 4 6, 7, 8
C123 BK Near PDC N/S C146 BK On EGR Solenoid 6, 7,8

C124 BK At Wiper Motor N/S C147 BK Injector No. 2 6, 7, 8
C125 BK Left Side of Dash Panel 3, 4 C148 BK On Throttle Body 6, 7, 8
C126 GY Left Side of Dash Panel 3, 4 C149 BK On Throttle Body (V-6, V-8, 6, 7, 8
V-10)
C127 GY Left Side of Dash Panel 3, 4
C149 BK On Injection Pump (Diesel) 9
C128 BK Above Left Front Body 2, 20
cushion C150 BK On Throttle Body 6, 7, 8
8W - 90 - 2 8W - 90 CONNECTOR/GROUND LOCATIONS
S C H E M A T I C S AND DIAGRAMS (Continued)
Conn # Color Location Fig, Conn # Color Location Fig.

C151 BK Front of Engine 6, 7, C177 BK Above Engine Starter Motor 9
8, 9 Q 1 7 8 BK Below Left Battery N/S
C152 BK Near Thermostat (V-6, V-8, ^ '> 5
C179 BK Below Left Battery N/S
V-10)
BK PDC, Near Battery 5, 24,
C152 BK Left Rear of Cylinder Head 9 25
(Diesel) n i
81 BK Starter Motor 5
C153 BK Rear of Intake Manifold c 7 o
BK A/C Low Pressure Cut-Out N/S
C154 BK Injector No. 9 9 Switch
C155 BK Injector No. 5 (V-6) 6
C183 BK Near PDC N/S
C155 BK Injector No. 7 (V-8, V-10) /
' 3
C184 BK At Intake Air Heater N/S
C156 BK injector No. 5 (V-8, V-10) 7
' 5
C185 BK Rear of Catalytic Convertor 26
C157 GY Right Side of Intake e
' 1
C185 BK Front of Catalytic Convertor 26
Manifold (V-6, V-8)
n-jAy BK Left Side of Transmission N/S
C157 BK Below Left Side of Intake 8
Manifold (V-10)
C191 BK Below Battery Tray 24
C158 BK Injector No. 3 fi. 7. 8 0 1 9 2 BK At Sensor 26
C159 BK Injector No. 1 6.7.8 0 1 9 3 BK At Sensor 26
C160 BK Right Exhaust Pipe 10, 11 0 1 9 4 BK At Sensor 26
C161 BK Top of Manual hfo C195 BK At Sensor N/S

Transmission C201 BK Left Kick Panel 19
C162 BK Left Exhaust Pipe 10, 11 C202 BK Bottom Left of LP. 14
C163 BK Rear of Transmission 10, 11 C203 BK Behind Switch 15
(2WD), Rear of Transfer C204 BK Near Headlamp Switch 14
Case (4WD)
C205 BK Rear of Airbag 14, 15
C164 BK Rear of A/C Compressor N / S
C206 BK Rear of Headlamp Switch 14
(V-6, V-8, Diesel)
0 2 0 7 BK Left Kick Panel 12, 19
C164 BK Rear of A/C Compressor ft
(V-10) C208 BK Near Fuse Block 13
C165 BK On A/C Compressor (V-10) 8 C209 BK Behind Knee Bolster N/S
C166 BK Side of Engine Block (V-10) 8 U210 BK On Steering Column 13, 15
C167 BK Side of Transmission 11 C212 BK At Ignition Switch 13, 15
C168 BK Diesel, EGR Intake N/S 0 2 1 3 BK At Ignition Switch 13, 15
Temperature Sensor C214 Top of Brake Pedal Arm 13
C169 BK Left Side of Transmission 11 C215 BK Rear of Instrument Cluster 12
C170 BK Right Front of Engine 6,7 C216 BK At Instrument Cluster 12
C171 BK Rear of Distributor 6, 7 C217 BK Near Rear of Fuse Block N/S
C172 BK On Dash Panel, Near N/S C218 BK On LP. Support, Right of 13
Master Cylinder Steering Column
C173 BK On Dash Panel, Near N/S C219 BK Top Center of LP, 12
Master Cylinder C223 3K Left Bottom of LP. 13
C174 BK Bottom of Fuel Filter/Water 9
C224 BK Behind Center of LP. 13
Separator
BK Behind Overdrive Switch 13
C175 BK Near Rear of Injection n .
Pump C226 GY Behind Fog Lamp Switch N/S
C176 BK Near EGR Engine Coolant N/S u 2 2 / BK Rear of HVAC Switch 12

Temperature Sensor C228 BK Center of LP. 12
Si* — — 8W - 90 CONNECTOR/GROUND LOCATIONS UW - 90 - 3
S C H E M A T I C S AND D I A G R A M S (Continued)
Conn # Color Location Fig. Conn # Coior Location Fig.

C229 GY Rear of Radio 14 C325 BK Right Door 19
C230 BK Rear of Radio 14 C326 BK Right Door 19
C231 BK Near Rear of Fuse Block N/S C327 BK Right Door 19
C232 BK Center of LP. at Airbag 12 C328 BK Top of Fue! Tank 20
Control Module C329 BK Below Right Tail Lamp 20, 22
C233 BK Center of IP, at Airbag 1 Z
C330 BK On Frame, Near Rear of 20
Controi Module Fuel Tank
C234 BK IP. Center Support l z
C331 BK Rear of Frame 20
C235 BK Center of LP. 1 3
C332 BK Rear of Frame 20
C236 BK Rear of Cigar Lighter 1 2
C333 BK Below Left Tail Lamp 20, 22
C237 BK Bottom Right of LP. 1 3
C334 BK Day/Night Mirror 16
C238 BK Bottom Right of IP. 1 3
C335 BK Behind Front of Headliner 16
C239 BK Right Side of Dash, Near- 1 2
Right Kick Panel
BK In Overhead Console N/S
C240 BK Right Side of Dash, Near 1°
Right Kick Panel
C241 BK At Fuse Block 16. 17 0 3 3 9 BK Behind Front of Headliner 16
C301 BK At Right Rear Speaker 17,18 C 3 4 0 BK Behind Front of Headliner 16
C302 BK At Right Rear Speaker 17/18 BK Behind Front of Headliner 16
C303 BK Below Driver's Seat 17. 18 C 3 4 2 BK Right Rear of Frame 20, 22
C304 BK Behind Dome Lamp 17, 18 0 3 4 3 BK Right Rear of Frame 20, 22
C305 BK At Left Rear Speaker 17, 18 0 3 4 5 BK Right Door N/S

0 3 4 6 BK Right Door N/S
C306 BK At Left Rear Speaker -17,-18
C307 BK In Body, Behind Left Door 17, 18 0 3 4 7 BK Left Door N/S
Opening C348 BK Left Door N/S
C308 BK Center Rear of Headliner 17, 18 C352 BK Left APillar 16
C309 BK Rear of Left Door Jamb N/S C353 BK Right APillar 16
Switch C401 BK Below LP, Right Side N/S
C310 BK Left Door 19 C402 BK At Forward Lamp on Left N/S
C311 BK Left Door 19 Fender
C312 BK Left Door 19 C403 BK At Forward Lamp on Right N/S
Fender
C313 BK Left Door 19
C314 BK Left Door 19 0 4 0 4 BK At Rear Lamp on Left N/S
Fender
C315 BK Left Door 10
^405 BK At Rear Lamp on Right N/S
C316 BK Left Door 19 Fender
C317 BK Left Door 1 9
C406 BK In Tailgate 22
C318 BK Left Door 1 y
C407 BK On Front of Frame 23
C319 BK Rear of Right Door Jamb N / S
C409 BK Left Frame Rail, Near Fuel 20
Switch Tank
C320 BK Right Door 1 y
C410 BK Rear of Lamp 21
C321 BK Right Door 19 C 4 1 1 BK Rear of Lamp 21
C322 BK Right Door iy C412 BK Rear of Lamp 21
C323 BK Right Door i y
C413 BK Rear of Lamp 21
C324 BK Right Door i y
C414 BK At Rear Bumper 22
8W - 90 - 4 — — 8W - 90 CONNECTOR/GROUND LOCATIONS — — BR
SCHEMATICS AND DIAGRAMS (Continued)
Conn # Color Location Fig. Conn # Color Location Fig.

C415 BK Rear of Lamp 22 G107 Near PDC 3
C416 BK Rear of Lamp 22 G108 Near PDC 3
C417 BK At Rear Bumper 22 G109 Left Fender Side Shield 8
C418 BK Rear of Lamp 22 G110 Below A/C Compressor 8
C419 BK Rear of Lamp 22 G111 Front of Right Frame Rail N/S
C420 BK Rear of Lamp N/S G112 Diesel, Front of Cylinder 9
C421 BK Rear of Lamp N/S Head
C422 BK Rear of Lamp N/S Below A/C Compressor 6, 7
C423 BK Rear of Lamp N/S Rear of A/C Compressor 8

(V-10)
C424 BK Rear of Lamp
nil ° Near Thermostat Housing 9
C425 BK Rear of Lamp N/S 0 1 1 3
'
(Diesel)
C426 BK Rear of Lamp N / S
G114 Left Side of Engine Block N/S
C427 BK On Trailer Hitch N/S (Diesel)
C428 BK Below Driver's Seat N/S Q115 Near Left Battery (Diesel) 25
C429 RD Below Driver's Seat N/S G116 From Left Battery (Diesel) N/S
C430 RD Below Driver's Seat N/S G117 Near Right Battery, Diesel 25
C431 BK Left Side of Driver's Seat N/S G118 Right Side of Engine Block N/S
C432 BK Rear of Fog Lamp 5 (Diesel)
C433 BK Rear of Fog Lamp 5 G119 Below A/C Compressor 6,7
N/S (V-6, V-8, V-10)
C434 BK At Sensor
C435 BK Left A-Pillar
G 2 0 1 LP. Right Center Support 14
1 6
C436 BK Right A-Pillar 1 f i G202 LP. Right Center Support 14
G101 Left Fender Side Shield p G203 LP. Left Center Support 14
G102 Left Fender Side Shield p G301 Below Left Rear Speaker 17, 18
G103 Right Fender Side Shield 1 G302 Left Kick Panel 19
G104 At Brake Master Cylinder 3 G303 Left Kick Panel 19
G105 Near PDC 3 G304 Front Center of Headliner 16
G106 Near Horns 2

Fig. 1 Engine Compartment Connectors
WINDSHIELD WASHER
HEADLAMP AND DASH RESERVOIR
WIRING HARNESS
TO RIGHT SIDE
OF ENGINE
COMPARTMENT LOW WASHER
FLUID SWITCH
WINDSHIELD WASHER
C131 (BLACK) PUMP MOTOR
C107 (BLACK) C108 (BLACK)

VIEW IN DIRECTION
OF ARROW Y
G101
G102
DAYTIME RUNNING GROUND
LAMP MODULE
VIEW IN DIRECTION LEFT FENDER
OF ARROW Z SIDE SHIELD
C113 (BLUE)
HEADLAMP
C112 (BLACK)
PARK AND TURN
FRONT BUMPER TO ENGINE SIGNAL LAMP
ASSEMBLY HORNS COMPARTMENT
WIRING VIEW IN DIRECTION
OF ARROW Y
G106
C128 (BLACK)
C129 (BLACK)
C116 (BLACK) LEFT FRONT
C115 (BLACK) BODY CUSHION 804facfb
Fig. 2 Engine Compartment Connectors — Front

HYDRAULIC CONTROL UNIT
LEFT FENDER POWER DISTRIBUTION
SIDE SHIELD CENTER C122 (BLACK) CONTROLLER
G105
G108 ANTI LOCK
G107 BRAKES
C120 (BLACK)
C119 (BLACK)
HAZARD HARNESS
CONNECTOR
DISTRIBUTION
CENTER
C121 (BLACK) POWER DISTRIBUTION

CONTROLLER CENTER
VIEW IN DIRECTION ANTI LOCK
OF ARROW Y BRAKES VIEW IN DIRECTION
BRAKE MASTER OF ARROW Z
CYLINDER G104
C118 (BLACK)
ABS FRONT WHEEL
SENSOR CONNECTOR
BRAKE WARNING VIEW IN DIRECTION
OF ARROW V
LAMP SWITCH
CONNECTOR
HEADLAMP AND DASH
WIRING HARNESS
C117 (BLACK)
POWERTRAIN
CONTROL MODULE
VIEW IN DIRECTION 0135
OF ARROW X C136
C137
Fig. 3 Engine Compartment Connectors — Left Side

C130 (BLACK)
UNDERHOOD LAMP
AND CONNECTOR
LEFT FENDER
SIDE SHIELD
VIEW IN DIRECTION
OF ARROW Z
C114 (BLACK) 0109 (BLACK)
AMBIENT AIR 0134 (BLACK) SPEED CONTROL
TEMPERATURE VACUUM SENSOR SERVO
C125 (BLACK) (DIESEL ONLY)
SENSOR 0126 (GRAY)
0127 (GRAY)
VIEW IN DIRECTION
LEFT FENDER OF ARROW T
POWER DISTRIBUTION
VIEW IN DIRECTION VIEW BN DIRECTION CENTER
OFARROW X OF ARROW Y
Fig. 4 Engine Compartment Connectors — Left Side

ft
O
C149 (BLACK) C165 (BLACK)
C158 (BLACK) THROTTLE POSITION FUEL
FUEL SENSOR INJECTOR 5
INJECTOR 3

FUEL IDLE AIR CONTROL
INJECTOR I MOTOR
TO GROUND 0139 (BLACK)

BATTERY ENGINE OIL PRESSURE
SENDING UNIT/SWITCH
0147 (BLACK)
C143 (BLACK) FUEL
FUEL INJECTOR 2
EVAP/PURGE C171 (BLACK)
INJECTOR 6
0145 (BLACK) SOLENOID CAMSHAFT
FUEL 0157 (GRAY) 0153 (BLACK)
INTAKE AIR POSITION
0146 (BLACK) INJECTOR 4 SENSOR
MiGR SOLENOID TEMPERATURE SENSOR
TRANSDUCER
0152 (BLACK) CRANKSHAFT
ENGINE COOLANT POSITION
TEMPERATURE SENSOR SENSOR
A/C COMPRESSOR
o
G119, G113 o
G111 o
0151 (BLACK)
0170 (BLACK) GENERATOR
DISTRIBUTOR
IGNITION COIL
ENGINE COOLANT
0138 (BLACK)
TEMPERATURE VIEW IN DIRECTION
VIEW IN DIRECTION SENDING UNIT
OF ARROW Y OFARROW X
Fig. 6 Engine Connectors — ¥-6 m

58
C158 (BLACK)
FUEL 0149 (BLACK)
C159 (BLACK) INJECTOR 3 0148 (BLACK)
FUEL THROTTLE POSTION MAP SENSOR
INJECTOR 1 SENSOR
0150 (BLACK)
IDLE AIR CONTROL
MOTOR
TO BATTERY
GROUND
0139 (BLACK)
ENGINE OIL
0142 (BLACK) PRESSURE SENDING
FUEL UNIT/SWITCH
INJECTOR 8 0156 (BLACK)
FUEL
0153 (BLACK) INJECTOR 5 0171 (BLACK)
EVAP/PURGE CAMSHAFT
0146 (BLACK) SOLENOID 0155 (BLACK) POSITION
EGR SOLENOID FUEL CRANKSHAFT SENSOR
TRANSDUCER C143 (BLACK) POSITION
FUEL INJECTOR 7
ASSEMBLY TO GENERATOR SENSOR
INJECTOR 6 DISCONNECT
A/0 COMPRESSOR
0152 (BLACK)
ENGINE COOLANT
TEMPERATURE
SENSOR
C145 (BLACK)
FUEL G119
INJECTOR 4 G113
0147 (BLACK)
FUEL
INJECTOR 2 VIEW IN DIRECTION
0151 (BLACK) OF ARROW X
0170 (BLACK) GENERATOR 0138 (SLACK)
ENGINE COOLANT
DISTRIBUTOR VIEW IN DIRECTION
IGNITION COIL TEMPERATURE
OF ARROW Z SENDING UNIT
Fig. 7 Engine Connectors — V-8

0145 (BLACK) 0156 (BLACK)
C146 (BLACK) INJECTOR #4 0154 (BLACK)
INJECTOR #5
EGR SOLENOID 0151 (BLACK) 0155 (BLACK) INJECTOR #9
GENERATOR 0157 (BLACK) INJECTOR #7
0143 (BLACK) INTAKE AIR
INJECTOR #6 0147 (BLACK) TEMPERATURE
INJECTOR #2 SENSOR
0142 (BLACK)
COOLANT G113
INJECTOR #8 TEMPERATURE
SENDING UNIT
INJECTOR # 1 0 ENGINE
COOLANT
0139 (BLACK) TEMPERATURE
OIL PRESSURE SENSOR
SENDING UNIT 0158 (BLACK)
0164 (BLACK) INJECTOR #3
A/C COMPRESSOR
CLUTCH
0159 (BLACK)
0138 (BLACK) 0166 (BLACK) INJECTOR #1
CRANKSHAFT CAMSHAFT 5 (BLACK)
POSITION POSITION A/C HIGH 'G109
SENSOR SENSOR G110 PRESSURE
SEE VIEW C SWITCH
0141 (BLACK) 0 1 5 0 (BLACK)

IGNITION COIL IDLE AIR CONTROL
PACK (4) MOTOR
0148 (BLACK)
MAP SENSOR 0149 (BLACK)
TPS SENSOR
0144 (BLACK)
IGNITION COIL 0153 (BLACK)
PACK EVAP/PURGE
(i) SOLENOID
Fig. 8 Engine Connectors — V-10

ENGINE WIRING C139 (BLACK) 0149 (BLACK)
HARNESS ENGINE OIL PRESSURE THROTTLE
SENDING UNIT POSITION
GENERATOR
(SENSOR)
POWER STEERNG
PUMP
FUEL
HEATER
VIEW INDIRECTION 0177 (BLACK)

OF ARROW X
V!EWIM_mRECTJOM VIEW IN DIRECTION

OF ARROW Z OF ARROW T
0151
(BLACK)
G119, G112 0157 (BLACK)
0174 (BLACK)
AIR HEATER WATER-IN INTAKE AIR
6113 ASSEMBLY FUEL SENSOR TEMPERATURE SENSOR
0152 (BLACK)
ENGINE COOLANT
0175 (BLACK) TEMPERATURE SENSOR
0138 (BLACK) FUEL SHUT-OFF
ENGINE SPEED VIEW IN DIRECTION VIEW IN DIRECTION
OFARROW T SOLENOID
SENSOR VIEW IN DIRECTION OF ARROWY
CONNECTOR OF ARROW X
Fig. 9 Engine Connectors — Diesel

ft »
O £
0161 (BLACK) X
BACK-UP LAMP m
TO ENGINE
WIRING
SWITCH
HEATED OXYGEN
SENSOR
0163 (BLACK)
VEHICLE SPEED
SENSOR
a
5
o
m
>
z©
©
TRANSFER
C163 (BLACK) CASE >
VEHICLE SPEED
W eo
SENSOR
O
o3 c©
#+ o
3.9L, 5.2L AND 5.9L
5" o
O
c
TO ENGINE 0160 (BLACK) a
WIRING
O
0161 (BLACK) 30
C163 (BLACK) O
BACK-UP LAMP
VEHICLE SPEED
SWITCH
0161 (BLACK) SENSOR
BACK-UP 0163 (BLACK)
TO ENGINE VEHICLE SPEED
LAMP SWITCH WIRING a
SENSOR i~
o
o
o
m
0162 (BLACK)
HEATED OXYGEN 5.9L HD DIESEL ENGINE
HEATED
80500504
Fig. 10 Manual Transmission Connectors

0169 (BLACK) 0160 (BLACK)
PARK NEUTRAL HEATED OXYGEN
TO ENGINE POSITION SWITCH SENSOR
WIRING
TO ENGINE
0167 (BLACK) WIRING
0163 (BLACK)
VEHICLE SPEED
SENSOR
DIESEL ENGINE 0163 (BLACK)

VEHICLE SPEED
SENSOR 0169 (BLACK)
PARK/NEUTRAL
HEATED OXYGEN POSITION 3.9L, 5.2L AND 5.9L
SENSOR SWITCH
0160 (BLACK)
TO ENGINE
WIRING
HEATED OXYGEN
0169 (BLACK) SENSOR
PARK/NEUTRAL
POSITION SWITCH TRANSFER
CASE
0167 (BLACK)
0163 (BLACK)
VEHICLE SPEED
SENSOR
*C195 (BLACK) 0163 (BLACK)
HEATED OXYGEN VEHICLE
SENSOR SPEED SENSOR
5.2L AND 5.9L HEAVY DUTY
Fig. 11 Automatic Transmission Connectors

0219 (BLACK)
C228 (BLACK) INTERMITTENT
CONTROLLER WIPER MODULE
ANTILOCK
BRAKES (RWAL)
0215 (BLACK)
INSTRUMENT INSTRUMENT CLUSTER
PANEL
0216 (BLACK)
INSTRUMENT CLUSTER VIEW IN DIRECTION
OF ARROW Y
TO INTERMITTENT
WIPER MODULE
(SEE VIEW Y)
FUSE BLOCK
AND RELAY BANK INSTRUMENT PANEL
ASSEMBLY
0240 (BLACK)
DOOR WIRING
0133 (BLACK)
C201 (BLACK) INSTRUMENT PANEL TO
C207 (BLACK) HEADLAMP AND DASH
DOOR WIRING WIRING CONNECTOR
VIEW IN DIRECTION
OF ARROW X
0239 (BLACK) TO HEADLAMP AND RADIO CHOKE
DOOR WIRING DASH WIRING AND RELAY
(SEE VIEW X) INSTRUMENT ASSEMBLY
PANEL
CONTROLLER SUPPORT
ANTILOCK
BRAKES (RWAL)
C234 (BLACK)
0236 (BLACK) (SEE VIEWY)
INSTRUMENT
CIGAR LIGHTER 0232 (BLACK) PANEL WIRING
AIRBAG CONTROL
MODULE VIEW IN DIRECTION
OF ARROW Z 80500506
Fig. 12 Instrument Panel Connectors

C218 (BLACK)
C235 (BLACK) BUZZER MODULE
AUXILIARY POWER INSTRUMENT SUPPORT
OUTLET CONNECTION (RIGHT OF STEERING COLUMN)
C224 (BLACK)
MESSAGE
CENTER
C225 (BLACK)
TRANSMISSON
OVERDRIVE SWITCH
C208 (BLACK)
ROOF WIRING
CONNECTOR
TO PARK B R A K E
SWITCH
C214 (BLACK)
STOP LAMP INSTRUMENT PANEL
SWITCH HARNESS
C210 (BLACK)
MULTI-FUNCTION
SWITCH
TO F U S E B L O C K
C238 (BLACK) •TO C L O C K S P R I N G

C212 (BLACK)
BLOWER IGNITION
MOTOR SWITCH
C213(BLACK)
IGNITION C223 (BLACK)
C237 (BLACK) SWITCH
RESISTOR DATA LINK
BLOCK CONNECTOR
VIEW IN DIRECTION
OF ARROW Z
80500507
Fig. 13 Instrument Panel Connectors

C229 (GRAY) § *
80500508
Fig. 14 Instrument Panel Ground Connections m

so
80500509 CO
Fig. 15 Steering Column Connectors

ROOF IDENTIFICATION
C335 (BLACK) LAMPS
C338 (BLACK)
OVERHEAD
CONSOLE
C334 (BLACK)
AUTOMATIC
DAY/NIGHT
MIRROR
C241 (FUSE)
C435 (BLACK) LEFT TO FUSE v
C436 (BLACK) RIGHT BLOCK

VISOR/VANITY
MIRROR LAMP
C352 (BLACK) LEFT
C353 (BLACK) RIGHT
VIEW IN DIRECTION VIEW IN DIRECTION

OF ARROW Y OF ARROW Z
Fig. 16 Overhead Console Connectors

m m
Fig. 17 Cab Connectors

8 1
Fig. 18 Extended Cab Connectors m

30
POWER MIRROR
POWER MIRROR SWITCH
DOOR LOCK SWITCH C311 (BLACK) LEFT DOOR C310 (BLACK)
C315 (BLACK) LEFT DOOR C322 (BLACK) RIGHT DOOR
C325 (BLACK) RIGHT DOOR
MIDRANGE DOOR SPEAKER

LEFT DOOR: C314(BLACK)
RIGHT DOOR: C324 (BLACK)
TO INSTRUMENT
DOOR SPEAKER • PANEL WIRING
LEFT DOOR:
C312(BLACK) OR
C313(BLACK)
RIGHT DOOR:
C320 (BLACK) OR
C323 (BLACK)
C201 (BLACK)
POWER WINDOW
POWER WINDOW SWITCH 10TOR
C316 (WHITE) LEFT DOOR 0318 (BLACK) LEFT DOOR
C326 (BLACK) RIGHT DOOR C321 (BLACK) RIGHT DOOR C207 (BLACK)
DOOR AJAR
SWITCH G302 (LEFT)
POWER DOOR G303 (RIGHT)
LOCK MOTOR
C317 (BLACK) LEFT DOOR VIEW IN DIRECTION
C327 (BLACK) RIGHT DOOR OFARROW X
8050050d
Fig. 19 Door Connectors

m »
o £
C 3 3 0 (BLACK) X .
C331 (BLACK) REAR WHEEL
OR.C332 (BLACK) SPEED SENSOR 2 <©
CHASSIS (TO C409 BLACK)
WIRING H ro
HARNESS
o *
>
z
a
a
>
0
30
FUEL TANK
X-MEMBER
FRAME f§ 00
ASSEMBLY
O
0
CO
3
3 o
C o
a z
C333 (BLACK)
LEFT TAIL
o
LAMP
o
c
CHASSIS WIRING a
HARNESS r—
o
o
C328 (BLACK)
FUEL
• C 1 2 9 (BLACK) TANK
MODULE J958W-17
Fig. 20 Frame Connectors

BR 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 25
J958W-236
Fig. 21 Center High Mounted Stop Lamps (CHMSL) and Cargo Lamps
C414 (BLACK) RIGHT
C417 (BLACK) LEFT
C406 (BLACK)
READ IDENTIFICATION
LAMPS
(W/DUAL REAR WHEELS ONLY)
C351 (BLACK) RIGHT

C416(BLACK) RIGHT
CAB AND CHASSIS C419 (BLACK) LEFT
Fig. 22 Rear Lamps

BR — — — 8W - 90 CONNECTOR/GROUND LOCATIONS
Fig. 23 Four Wheel Drive Switch

Fig. 24 Battery Connections 09
33
80500512 CO
Fig. 25 Diesei Battery Connections
C194 (BLACK)
POST CATALYST
HEATED RIGHT SIDE
OXYGEN SENSOR
Fig. 26 Heated Oxygen Sensor Connectors — V-10 Engine 03

30
BR SW - 95 SPLICE LOCATIONS 8W - 95 -1
8W-95 SPLICE LOCATIONS
INTRODUCTION SPLICE LOCATIONS

This section provides illustrations identifying the For splices that are not shown in the figures in
general location of the splices in this vehicle. A splice this section, N/S is placed in the Fig. column.
index is provided. Use the wiring diagrams in each
section for splice number identification. Refer to the
index for proper splice number.
Splice Location Fig. Splice Location Fig.

Number Number
S101 In T/O for Right Turn Signal Lamp 1 S121 In Branch to IP. Harness, On LP. 2
S102 In T/O for Right Turn Signal Lamp 1 Side of Grommet
S103 Before T/O for Right Headlamp 1 SI 22 In Branch to IP. Harness, On IP. 2
Side of Grommet
S104 Near Horn T/O 1
o-t n o In T/O for Left Turn Signal Lamp 1
O 1 c.O
S105 In Branch for Horn T/O CM o n
O 1 C-3
Near Branch to Injectors 2, 4, 6, 8 2
S106 After Branch for Horn T/O
(V-6, V-8)
S107 Before Branch for Controller 2
S129 Before Branch to Injectors 2, 4, 6, 2
Antilock Brakes (CAB) 8, 10 (V-10)
S130 Near Branch to Injectors 2, 4, 6, 8 2
Antilock Brakes (CAB) (V-6, V-8)
S130 Near Branch to Injectors 2, 4, 6, 2
Antilock Brakes (CAB) 8, 10 (V-10)
S110 In Branch to Controller Antilock 2
S130 After T/O to Engine Coolant 5
Brakes Temperature Sending Unit (Diesel)
S111 In Branch to Controller Antilock 2
S131 After Branch to Injectors 2, 4, 6, 8 2
Brakes (V-6, V-8)
S112 In T/O to Hydraulic Control Unit 2
S131 After Branch to Injectors 2, 4, 6, 8, 2
S113 Before T/O for PDC 2 10 (V-10)
S114 Before Branch to Engine Harness 2 S131 Before PCM (Diesel) 2
Connectors S132 After Branch to Injectors 2, 4, 6, 8 2
S115 Before Branch to Engine Harness 2 (V-6, V-8)
Connectors S132- • After Branch to Injectors 2, 4, 6, 8, 2
S116 In Branch to Engine Harness 2 10 (V-10)
Connectors S132 Rear of Engine 5
S117 In Branch to Engine Harness 2
S133 After T/O for Idle Air Control Motor 3
Connectors (V-6, V-8)
S118 In T/O to Chassis Connector 1
S133 Near T/O for Injector 5 (V-10) 4
(C128)
^ O 1 OH- Between T/Os for Injectors 4 and 3
S119 In T/O to Chassis Connector
6 (V-6, V-8)
(C128)
^ O 1 OH Between T/Os for Injectors 6 and 4
S120 In T/O to Chassis Connector
8 (V-10)
(C128)
S134 Near Branch to Fuel Heater 5
(Diesel)
8W - 95 - 2 8W - 95 SPLICE LOCATIONS
S C H E M A T I C S A N D D I A G R A M S (Continued)

Number Number
S135 Between T/Os for Injectors 4 and 3 S150 In Branch to Ground G119 (V-6, 3
6 (V-6, V-8) V-8)
S135 Between T/Os for Injectors 4 and 4 S150 In Branch to Ground G119 (V-10) 4
6 (V-10) SI 51 After Branch to Injectors 1, 3, 5, 7 2
S136 Near Crankshaft Position Sensor 2 (V-6, V-8, V-10)
T/O (V-6, V-8) S152 Near T/O for Fuel Heater Relay 2
S136 Between T/Os for Injectors 5 and 4 S153 In T/O to Chassis Connector 1
7 (V-10) (C128)
S136 Between T/Os for Intake Air 5
S154 Before Branch to Injectors 1, 3, 5, 2
Heaters and Fuel Heater (Diesel) 7 (V-6, V-8)
S137 Near Distributor T/O (V-6, V-8) 3
S I 54 Before Branch to Injectors 1, 3, 5, 2
S137 Near T/O to Idle Air Control Motor 4 7, 9 (V-10)
(V-10) S155 In PDC 2
S138 After T/Os for Injectors 2, 4, 6, 8 6
S156 In Branch to Engine Harness 2
(V-6, V-8) Connectors
S138 After Branch to Injectors 2, 4, 6, 8, z
S157 Between T/Os for Intake Air 5
10 (V-10) Heaters and Fuel Heater (Diesel)
S139 Near T/Os for PCM Connectors 2
S158 In Branch to Controller, Antilock 2
(V-6, V-8) Brakes
S139 Near T/Os for PCM Connectors z
S159 Before PCM (Diesel) 2
(V-10) n
S1^ Before T/Os for Headlamp and 2
S140 Before T/Os for Headlamp and 2 Dash Harness Connectors
Dash Harness Connectors (V-6,
S201 In Fuse Block N/S
V-8)
S140 After Branch to Injectors 1, 3, 5, 7, -S202 In Fuse Block N/S
9, (V-10) S203 In Headlamp Switch T/O 7
S140 Between T/Os for Intake Air 5 S204 In Headlamp Switch T/O 7
Heaters and Fuel Heater (Diesei) S205 Near Headlamp Switch T/O 7
S141 In Branch to Transmission Wiring 3 S206 In Fuse Block T/O 7
(V-6, V-8) S207 Between T/Os for Cluster 7
S141 Before Branch to Oxygen Sensors 6 Connectors
and Vehicle Speed Sensor
S208 Between T/Os for Cluster 7
S141 Before PCM (Diesel) 2 Connectors
SI 42 Near T/O for Fuel Shut-Off 5 S209 After Cluster Connector T/Os 7
Solenoid
S143 Between T/Os for Intake Air 5 ____ After Wiper Module T/O
Near Radio Choke Relay T/O
7
7
Heaters and Fuel Heater (Diesel)
In Radio Choke Relay T/O T
/
S144 In Harness to Left Battery Positive N/.Q 8 2 1 3
Terminal S214 After Power Outlet T/O 7

S145 In Harness to Left Battery Positive N/S 8 2 1 5 After Airbag Control Module T/O 7
Terminal S216 Before Glove Box T/O 7
S146 In PDC 2 S217 After Glove Box T/O 7
S147 In PDC 2 S218 In Branch to Power Door Lock 7
S148 Battery Positive Harness N/S Switch and Power Mirror Switch
S149 In T/O to Chassis Connector C128 ^ ~ S301 Near T/O for Body Ground G301 9
S302 Near Left Rear Speaker T/O 9
BR 8W - 95 SPLICE LOCATIONS 8W - 95 - 3
S C H E M A T I C S AND DIAGRAMS (Continued)

Number Number
S303 Near Body Ground (G301) 9 S317 After T/O for Left Outboard 8
S304 In Left Door Speaker T/O 10 Clearance Lamp
S305 In Left Power Mirror Motor T/O 10 S318 After T/O for Left Outboard 8
Clearance Lamp
S306 In Left Door Harness 10
S319 Before T/O to Center Identification 8
S307 In Right Door Speaker T/O 10
Lamp
S308 In Right Door Power Window 10
S320 Before T/O to Center Identification 8
Motor T/O
Lamp
S309 Before T/O to Door Switch 10
S401 In Tail Lamp Jumper Harness N/S
S310 Before T/O to Door Switch 10
S402 In Tail Lamp Jumper Harness N/S
S311 Near Fuel Pump Module T/O 11
S403 In Air Intake Heater Feed N/S
S312 After Branch to Right Rear Lamps 11
S404 In Air Intake Heater Feed N/S
S405 In Fender Lamps Harness N/S
S406 In Fender Lamps Harness N/S
S315 In T/O to Trailer Tow Harness 11
S407 In Tailgate Harness N/S
Connectors
S408 In Tailgate Harness N/S
S316 In T/O to Trailer Tow Harness 11
Connectors S409 in Branch to Right Fog Lamp 12
80500513
Fig. 1 Engine Compartment Wiring Splices — Front
m
0 m
X
VIEW IN DIRECTION S121 m
OFARROW Z
m
1
W
S156
S109
S114
©
S112 >
a
CO
m
o
o CO
CJ1
S154 (V-6/V-8) 3
S129 £ co
VIEW IN DIRECTION S107 S159 S152 (DIESEL)
OF ARROW Y S160 (V-6, 3 -O
(DIES
V-8, V-10) c E
en O
ft "1
O
o
CO
S146
S145
S155
(IN PDC)
S140
VIEW IN DIRECTION
OF ARROW W S131 (DIESEL) (DIESEL) S131 (V/6,
oo
V/8, V/10)
co
CJl
Fig. 2 Engine Compartment Wiring Splices — Rear
8W - 95 - 6 — — — 8W - 95 SPLICE LOCATIONS
SCHEMATICS AND DIAGRAMS (Continued)
BR 8W - 95 SPLICE LOCATIONS 8W - 95 - 9
80500540
Fig. 6 Transmission Wiring Splices

8W - 95 - 10 _ _ _ _ _ 8W - 95 SPLICE LOCATIONS
8W - 95 - 1 4 _ _ _ _ _ _ _ 8W - 95 SPLICE LOCATIONS BR
S C H E M A T I C S AND D I A G R A M S ( C o n t i n u e d )
BR ENGINE 9 -1
ENGINE
CONTENTS
page page
3.9L ENGINE 23 8.0L ENGINE 127

5.2L ENGINE 58 ENGINE DIAGNOSIS 7
5.9L (DIESEL) ENGINE 163 STANDARD SERVICE INFORMATION 1
5.9L ENGINE 93
S T A N D A R D S E R V I C E INFORMATION
INDEX
page page
G E N E R A L INFORMATION MEASURING WITH PLASTIGAGE 2

ENGINE OIL SERVICE 4 SERVICE PROCEDURES
ENGINE PERFORMANCE—GASOLINE HONING CYLINDER BORES . . . 6
ENGINES 2 HYDROSTATIC LOCK . . . .. 6
FORM-IN-PLACE GASKETS—GASOLINE REPAIR DAMAGED OR WORN THREADS . . . . . . 5
ENGINES 1
GENERAL INFORMATION properly cure i f over-aged. Always inspect the pack

age for the expiration date before use.
FORM-IN-PLACE GASKETS—GASOLINE ENGINES
There are several places where form-in-place gas MOPAR® GASKET MAKER
kets are used on the engine. DO NOT use form-in- Mopar® Gasket Maker, normally red in color, is
place gasket material unless specified. Care available in six-cc tubes. This anaerobic type gasket
must be taken when applying form-in-place gaskets. material cures in the absence of air when squeezed
Bead size, continuity, and location are of great impor between smooth machined metallic surfaces.' I t will
tance. Too-thin a bead can result in leakage, while not cure i f left in the uncovered tube. DO NOT use
too much can result in spill-over. A continuous bead on flexible metal flanges.
of the proper width is essential to obtain a leak-free
SURFACE PREPARATION
joint.
Parts assembled with form-in-place gaskets may be
Two types of form-in-place gasket materials are
disassembled without unusual effort. In some
used i n the engine area (Mopar® Silicone Rubber
instances, it may be necessary to lightly tap the part
Adhesive Sealant and Mopar® Gasket Maker). Each
with a mallet, or other suitable tool, to break the seal
has different properties and they cannot be used
between the mating surfaces. A flat gasket-scraper
interchangeably.
may also be lightly tapped into the joint, but care
MOPAR® SILICONE RUBBER ADHESIVE must be taken not to damage the mating surfaces.
SEALANT Scrape or wire brush all gasket surfaces to remove
Mopar® Silicone Rubber Adhesive Sealant, nor all loose material. Inspect stamped parts to ensure
mally black in color, is available in both three ounce that gasket rails are flat. Flatten rails with a ham
tubes and four and one-half ounce power tubes. Mois mer on a flat plate, i f required. Gasket surfaces must •
ture i n the air causes the sealant material to cure. be free of oil and dirt. Be sure the old gasket mate
This material is normally used on flexible metal rial is removed from blind attaching holes.
flanges. The tubes have a shelf life of one year and
the power tubes two years shelf life, and will not
9 -2 ENGINE

GASKET APPLICATION (f) Be sure throttle blades are fully open during
Assembling parts using a form-in-place gasket the compression check.
requires care. (g) Insert compression gauge adaptor into the
Mopar® Silicone Rubber Adhesive Sealant should No.l spark plug hole. Crank engine until maxi
be applied in a continuous bead approximately 3 mm mum pressure is reached on gauge. Record this
(0.12 inch) in diameter. All mounting holes must be pressure as N o . l cylinder pressure.
circled. For corner sealing, a 3 or 6 mm (1/8 or 1/4 (h) Repeat Step 3g for all remaining cylinders.
inch) drop is placed in the center of the gasket con (i) Compression should not be less than 689 kPa
tact area. Uncured sealant may be removed with a (100 psi) and not vary more than 172 kPa (25 psi)
shop towel. Components should be torqued in place from cylinder to cylinder.
while the sealant is still wet to the touch (within ten (j) I f cylinders) have abnormally low compres
minutes). The use of a locating dowel is recom sion pressures, repeat steps 3a through 3h.
mended during assembly to prevent smearing the (k) I f the same cylinder(s) repeat an abnormally
material off location. low reading, it could indicate the existence of a
Mopar® Gasket Maker should be applied sparingly problem in the cylinder.
to one gasket surface. The sealant diameter should
be 1.00 mm (0.04 inch) or less. Be certain the mate NOTE: The recommended compression pressures
rial surrounds each mounting hole. Excess material are to be used only a s a guide to diagnosing engine
can be easily wiped off. Components should be problems. An engine should NOT be disassembled
torqued in place within 15 minutes. The use of a to determine the cause of low compression unless
locating dowel is recommended during assembly to some malfunction is present.
prevent smearing the material off location.
(4) Clean or replace spark plugs as necessary.
ENGINE PERFORMANCE—GASOLINE ENGINES Adjust gap. Refer to Group 8D, Ignition System, for
To provide best vehicle performance and lowest gap adjustment and torque specifications.
vehicle emissions, i t is most important that the (5) Test resistance of spark plug cables. Refer to
tune-up be done accurately.. Use the specifications Group 8D, Ignition System, for procedure.
listed on the Vehicle Emissions Control Information (6) Inspect the primary wire. Test coil output volt
label found on the engine compartment hood. age, primary and secondary resistance. Replace parts
(1) Test cranking amperage draw. Refer to Group as necessary. Refer to Group 8D, Ignition System,
8B, Battery/Starter/Generator Service, for the proper and make necessary adjustment.
procedures. (7) Set ignition timing to specifications. Refer to
(2) Tighten the intake manifold bolts. Refer to Specification Label on engine compartment hood.
Group 11, Exhaust System and Intake Manifold, for (This step does not apply to 8.0L engines.)
the proper procedure and torque specifications. (8) Perform a combustion analysis.
(9) Test fuel pump for pressure and vacuum. Refer
CAUTION: DO NOT overspeed the engine. to Group 14, Fuel System, for the proper specifica
tions.
(3) Perform cylinder compression test: (10) Inspect air filter element. Refer to Group 0,
(a) Check engine oil level and add oil, i f neces Lubrication and Maintenance, for the proper proce
sary. dure.
(b) Drive the vehicle until engine reaches nor (11) Inspect crankcase ventilation system. Refer to
mal operating temperature. Group 0, Lubrication and Maintenance, for the
(c) Select a route free from traffic and other proper procedure.
forms of congestion, observe all traffic laws, and (12) For emissions controls, refer to Group 25,
briskly accelerate through the gears several times. Emissions Controls System for service procedures.
The higher engine speed may help clean out valve (13) Inspect and adjust accessory belt drives. Refer
seat deposits, which can prevent accurate compres to Group 7, Cooling System, for the proper adjust
sion readings. ments.
(d) Remove all spark plugs from engine. As (14) Road-test vehicle as a final test.
spark plugs are being removed, check electrodes for
abnormal firing indicators—fouled, hot, oily, etc. MEASURING WITH PLASTIGAGE
Record cylinder number of each spark plug for
future reference. C R A N K S H A F T MAIN BEARING CLEARANCE
(e) Disconnect coil wire from distributor or from Engine crankshaft bearing clearances can be deter
both coil packs (V-10) and secure to good ground to mined by use of Plastigage, or equivalent. The follow-
prevent a spark from starting a fire.
BR ENGINE 1-3
ing is the recommended procedure for the use of
Plastigage:
(1) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(2) The total clearance of the main bearings can be
determined only by removing the weight of the
crankshaft. This can be accomplished by either of two
methods:
METHOD -1 (PREFERRED)
Shim the bearings adjacent to the bearing to be
checked. This' will remove the clearance between
upper bearing shell and the- crankshaft. Place a min Fig. 1 Placement of Plastigage in Bearing Shell
imum of 0.254 mm (0.010 in.) shim between the bear ferences in readings between the ends indicate the
ing shell and the adjacent bearing cap. Tighten the amount of taper present. Record all readings taken.
bolts to 18 N-m (13 ft. lbs.) torque. Refer to Engine Specifications.
• C H E C K NO. 1 BEARING: Shim No. 2 main
bearing.
• C H E C K NO* 2 BEAMING: Shim No. 1 and No.
3 main bearing.
• C H E C K NO. 3 BEAMING: Shim No. 2 and No.
4 main bearing.
• C H E C K NO* .4 BEARING: Shim No. 3 main
bearing (3.9L). Shim No. 3 and No. 5 main bearing
(5.2L, 5.9L, 8.0L and 5.9L-Diesel).
• C H E C K M M BEARING: Shim No. 4 main
bearing (5.2L and 5.9L). Shim No. 4 and No. 6 main RN861
bearing (8.0L and 5.9L-Diesel).
• C H E C K NO* 6 BEARING: Shim No. 5 main Fig. 2 Clearance Measurement
bearing (8.0L). Shim No. 5 and No. 7 main bearing
(3) Plastigage is available in a variety of clearance
(5.9L-Diesel). -
ranges. The 0.025-0.076 mm (0.001-0.003 in.) range
• C H E C K NO. 7 BEARING: Shim No. 6 main
is usually the most appropriate for checking engine
bearing (5.9L-Diesel).
bearing clearances.
NOTE; Remove ail shims before assembling
coMMEcnmm moo B E A R I M G C L E A R A N C E
engine,
Engine connecting rod bearing clearances can be
determined by use of Plastigage, or equivalent. The
METHOD - 2 (ALTERNATIVE) following is the recommended procedure for the use
Support the weight of the crankshaft with a jack of Plastigage:
placed under the counterweight adjacent to the bear (1) Remove oil film from surface to be checked.
ing being checked. Plastigage is soluble in oil.
(1) Place a piece of Plastigage across the entire (2) Place a piece of Plastigage across the entire
width of the bearing cap shell (Fig. 1). Position the width of the bearing cap shell (Fig. 1). Position the
Plastigage approximately 6.35 mm (1/4 in.) off center Plastigage approximately 6.35 mm (1/4 inch) off cen
and away from the oil holes. In addition, suspect ter and away from the oil holes. In addition, suspect
areas can be checked by placing the Plastigage in areas can be checked by placing the Plastigage in the
that area. Tighten the bearing cap bolts of the bear suspect area.
ing being checked to 115 N-m (85 ft. lbs.) torque. DO (3) The crankshaft must be rotated until the con
NOT rotate the crankshaft or the Plastigage necting rod to be checked starts moving toward the
may be smeared, giving inaccurate results. top of the engine. Only then should the rod cap, with
(2) Remove the bearing cap and compare the width Plastigage in place, be assembled. Tighten the rod
of the flattened Plastigage with the scale provided on cap nut to 61 N-m (45 ft. lbs.) torque. DO NOT
the package (Fig. 2). Plastigage generally comes in rotate the crankshaft or the Plastigage may be
two scales (one scale is in inches and the other is a smeared, giving inaccurate results.
metric scale). Locate the band closest to the same (4) Remove the bearing cap and compare the width
width. This band shows the amount of clearance. Dif- of the flattened Plastigage with the scale provided on
^ iTT,
I -4 ENGINE mmmm
the package (Fig. 2). Plastigage generally comes in
two scales (one scale is in inches and the other is a
metric scale). Locate the band closest to the same :0W-30
width. This band shows the amount of clearance. Dif
ferences in readings between the ends indicate the < 5W-30
amount of taper present. Record all readings taken.

Refer to Engine Specifications. F —20
i
0
l
10
i
20 32 60 80 100
(5) Plastigage is available in a variety of clearance C -29 -18 -12 -7 0 16 27 38
ranges. The 0.025-0.076 mm (0.001-0.003 in.) range ANTICIPATED TEMPERATURE RANGE

BEFORE NEXT OIL CHANGE J9000-39
is usually the most appropriate for checking engine
bearing clearances.
Fig. 3 Temperature/Engine Oil Viscosity
ENGINE OIL SERVICE CONTAINER IDENTIFICATION
Standard engine-oil identification notations have
WARNING: NEW OR USED ENGINE OIL CAN BE been adopted to aid in the proper selection of engine
IRRITATING TO THE SKIN. AVOID PROLONGED OR oil. The identifying notations are located on the label
REPEATED SKIN CONTACT WITH ENGINE OIL of engine oil plastic bottles and the top of engine oil
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY cans (Fig. 4).
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE. DISPOSE OF USED ENGINE OIL
PROPERLY.
ENGINE OIL SPECIFICATION
9400-9
CAUTION: Do not * use non-detergent or straight
mineral oil when adding or changing crankcase
Fig. 4 Engine Oil Container Standard Notations
lubricant. Engine failure can result.
engine-oil additives
In some instances, such as infrequent operation,
A P I service GRADE CERTIFIED short-trip driving, and during break-in after a major
Use an engine oil that is API Service Grade Certi overhaul, addition of special materials containing
fied or an oil that conforms to the API Service Grade anti-rust and anti-scuff additives are beneficial. A
SH or SH/CD. MOPAR provides engine oils that con suitable product for this purpose is MOPAR Engine
form to all of these service grades. Oil Supplement.
SAE VISCOSITY CRANKCASE GIL LEVEL INSPECTION
An SAE viscosity grade is used to specify the vis
cosity of engine oil. SAE 30 specifies a single- viscos CAUTION: Do not overfill crankcase with engine
ity engine oil. Some engine oils also have multiple oil, oil foaming and oil pressure loss can result.
viscosities. These are specified with a dual SAE vis
cosity grade which indicates the cold-to-hot tempera To ensure proper lubrication of an engine, the
ture viscosity range. Select an engine oil that is best engine oil must be maintained at an acceptable level.
suited to your area's particular temperature range The acceptable oil level is i n the SAFE RANGE on
and variation (Fig. 3). the engine oil dipstick (Fig. 5).
Unless the engine has exhibited loss of oil pres
ENERGY-CONSERVING OIL sure, run the engine for about five minutes before
An Energy Conserving type oil is recommended for checking oil level. Checking engine oil level of a cold
gasoline engines. They are designated as either engine is not accurate.
ENERGY CONSERVING or ENERGY CONSERV (1) Position vehicle on level surface.
ING I I . (2) With engine OFF, allow approximately ten min
utes for oil to settle to bottom of crankcase, remove
engine oil dipstick.
(3) Wipe dipstick clean.
BR . - • — — ENGINE 9-5

(3) Rotate the oil filter counterclockwise to remove
it from the cylinder block oil filter boss (Fig. 6).
Fig. 5 Oii Level Indicator (Dipstick)

(4) Replace dipstick and verify i t is seated in the
tube. Fig. 6 Oil Filter Removal—Typical
(5) Remove dipstick, with handle held above the
tip, take oil level reading. (4) When filter separates from adapter nipple, tip
(6) Add oil only i f level is below the SAFE RANGE gasket end upward to minimize oil spill. Remove fil
area on the dipstick. ter from vehicle.
(7) Replace dipstick (5) With a wiping cloth, clean the gasket sealing
surface (Fig. 7) of oil and grime.
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals OIL FILTER INSTALLATION
described in the Maintenance Schedule. (1) Lightly lubricate oil filter gasket with engine
oil or chassis grease.
TO CHANGE ENGINE OIL (2) Thread filter onto adapter nipple. When gasket
Run engine until normal operating temperature is makes contact with sealing surface, (Fig. 7) hand
achieved. tighten filter one full turn, do not over tighten.
(1) Position the vehicle on a level surface and turn (3) Add oil, verify crankcase oil level, and start
off engine. engine. Inspect for oil leaks.
(2) Hoist and support vehicle on safety stands.
Refer to Hoisting and Jacking Recommendations.
(3) Remove oil fill cap.
(4) Place a suitable drain pan under crankcase
drain.
(5) Remove drain plug from crankcase and allow
oil to drain into pan. Inspect drain plug threads for
stretching or other damage. Replace drain plug and
gasket, i f damaged.
(6) Install drain plug in crankcase.
(7) Lower vehicle and fill crankcase with specified
type and amount of engine oil described in this section.
(8) Install oil fill cap. Fig. 7 Oil Filter Sealing Surface—Typical
(9) Start engine and inspect for leaks. USED ENGINE OIL DISPOSAL
(10) Stop engine and inspect oil level. Care should be exercised when disposing of used
ENGINE OIL FILTER CHANGE
engine oil after i t has been drained from a vehicle's
engine.
FILTER SPECIFICATION
All Dodge Ram engines are equipped with a high SERVICE PROCEDURES
quality full-flow, disposable type oil filter. Chrysler
Corporation recommends a Mopar, or equivalent, oil REPAIR DAMAGED OR WORN THREADS
filter be used.
Damaged or worn threads can be repaired. Essen
OIL FILTER RE10WAL
tially, this repair consists of:
• Drilling out worn or damaged threads.
(1) Position a drain pan under the oil filter.
• Tapping the hole with a special Heli-Coil Tap, or
(2) Using a suitable oil filter wrench, loosen filter.
equivalent.
• Installing an Insert Into the tapped hole to bring (4) A controlled hone motor speed between 200 and
the hole back to its original thread size. 300 RPM is necessary to obtain the proper Crosshatch
angle. The number of up and down strokes per minute
CAUTION: Be sure that the tapped holes maintain can be regulated to get the desired 50° to 60° angle.
the original center line. Faster up and down strokes increase the Crosshatch
angle.
Heli-Coil tools and inserts are readily available (5) After honing, it is necessary that the block be
from automotive parts jobbers. cleaned to remove all traces of abrasive. Use a brush
to wash parts with a solution of hot water and deter
HONING CYLINDER BORES gent. Dry parts thoroughly. Use a clean, white, lint-
Before honing, stuff plenty of clean shop towels free cloth to check that the bore is clean. Oil the
under the bores and over the crankshaft to keep bores after cleaning to prevent rusting.
abrasive materials from entering the crankshaft
area. HYDROSTATIC LOCK
(1) Used carefully, the Cylinder Bore Sizing Hone When an engine is suspected of hydrostatic lock
C-823, equipped with 220 grit stones, Is the best tool for (regardless of what caused the problem), follow the
this job. In addition to deglazing, it will reduce taper steps below.
and out-of-round, as well as removing light scuffing, (1) Perform the Fuel Pressure Release Procedure.
scoring and scratches. Usually, a few strokes will clean Refer to Group 14, Fuel System.
up a bore and maintain the required limits. (2) Disconnect the negative cable from the battery.
(3) Inspect air cleaner, induction system, and
CAUTION: DO NOT use rigid type hones to remove
intake manifold to ensure system is dry and clear of
cylinder wall glaze.
foreign material.
(2) Deglazing of the cylinder walls may be done i f (4) Place a shop towel around the spark plugs or
the cylinder bore is straight and round. Use a cylin fuel injectors (diesel engine) to catch any fluid that
der surfacing hone, Honing Tool C-3501, equipped may possibly be under pressure in the cylinder head.
with 280 grit stones (C-3501-3810). about 20-60 Remove the spark plugs or fuel injectors (diesel
strokes, depending on the bore condition, will be suf engine).
ficient to provide a satisfactory surface. Using honing
CAUTION: DO NOT use the starter motor to rotate
oil C-3501-3880, or a light honing oil, available from
the crankshaft. Severe damage could occur.
major oil distributors.
(5) With all spark plugs and injectors (diesel
CAUTION: DO NOT use engine or transmission oil,
engine) removed, rotate the crankshaft using a
mineral spirits, or kerosene.
breaker bar and socket.
(3) Honing should be done by moving the hone up (6) Identify the fluid in the cylinders (coolant, fuel,
and down fast enough to get a Crosshatch pattern. oil, etc.).
The hone marks should INTERSECT at 50° to 60° ( 7 ) Be sure all fluid has been removed from the
for proper seating of rings (Fig. 8). cylinders.
(8) Repair engine or components as necessary to
CROSSHATCH s prevent this problem from occurring again.
( 9 ) Squirt engine oil into the cylinders to lubricate
the walls. This will prevent damage on restart.
(10) Install new spark plugs or fuel injectors (die
sel engine). Tighten the spark plugs to 41 N-m (30 ft.
lbs.) torque. Tighten the fuel injector nuts to 60 N-m
(11) Drain engine oil. Remove and discard the oil
filter.
(12) Install the drain plug. Tighten the plug to 34
(13) Install a new oil filter.
(14) Fill engine crankcase with the specified
amount and grade of oil. Refer to Group 0, Lubrica
tion and Maintenance.
(15) Connect the negative cable to the battery.
Fig. 8 Cylinder Bore Crosshatch Pattern (16) Start the engine and check for any leaks.
BR — — • — — — — — — — — ENGINE 9-7
ENGINE DIAGNOSIS
INDEX
page page
DIAGNOSIS AND TESTING HYDRAULIC TAPPETS 9

CYLINDER COMBUSTION PRESSURE INSPECTION (ENGINE OIL LEAKS IN
LEAKAGE TEST 8 GENERAL) 8
CYLINDER COMPRESSION PRESSURE TEST . . 7 INSPECTION FOR REAR SEAL AREA LEAKS . . . 9
ENGINE CYLINDER HEAD GASKET FAILURE INTAKE MANIFOLD LEAKAGE DIAGNOSIS 7
DIAGNOSIS .. 7 SERVICE DIAGNOSIS—DIESEL-
ENGINE DIAGNOSIS—GASOLINE- MECHANICAL 21
MECHANICAL 12 SERVICE DIAGNOSIS—DIESEL-
ENGINE DIAGNOSIS—GASOLINE- PERFORMANCE 14
PERFORMANCE 11 SERVICE DIAGNOSIS—GASOLINE-
ENGINE OIL PRESSURE 10 LUBRICATION 13
GENERAL INFORMATION .7
DIAGNOSIS AND T E S T I N G (2) Spray a small stream of water at the suspected

leak area.
GENERAL INFORMATION (3) I f a change in RPMs, the area of the suspected
Engine diagnosis is helpful in determining the leak has been found.
causes of malfunctions not detected and remedied by (4) Repair as required.
routine tune-ups.
These malfunctions may be classified as either CYLINDER COMPRESSION P R E S S U R E TEST
mechanical (e.g., a strange noise), or performance The results of a cylinder compression pressure test
(e.g., engine idles rough and stalls). can be utilized to diagnose several engine malfunc
Refer to the Service Diagnosis—Mechanical Chart tions.
and the Service Diagnosis—Performance Chart, for Ensure the battery is completely charged and the
possible causes and corrections of malfunctions. Refer engine starter motor is in good operating condition.
to Group 14, Fuel System, for the fuel system diag Otherwise, the indicated compression pressures may
nosis. not be valid for diagnosis purposes.
Additional tests and diagnostic procedures may be (1) Clean the spark plug recesses with compressed
necessary for specific engine malfunctions that can air.
not be isolated with the Service Diagnosis charts. (2) Remove the spark plugs.
Information concerning additional tests and diagno (3) Secure the throttle in the wide-open position.
sis is provided within the following: (4) Disconnect the ignition coil.
• Cylinder Compression Pressure Test (5) Insert a compression pressure gauge and rotate
• Cylinder Combustion Pressure Leakage Test the engine with the engine starter motor for three
• Engine Cylinder Head Gasket Failure Diagnosis revolutions.
• Intake Manifold Leakage Diagnosis (6) Record the compression pressure on the third
revolution. Continue the test for the remaining cylin
INTAKE MANIFOLD LEAKAGE DIAGNOSIS ders.
An intake manifold air leak is characterized by Refer to Engine Specifications for the correct
lower than normal manifold vacuum. Also, one or engine compression pressures.
more cylinders may not be functioning.
ENGINE CYLINDER HEAD GASKET FAILURE
WARNING: U S E EXTREME CAUTION WHEN T H E DIAGNOSIS
ENGINE IS OPERATING. DO NOT STAND IN A A leaking engine cylinder head gasket usually
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR results in loss of power, loss of coolant, and engine
HANDS NEAR T H E P U L L E Y S , B E L T S , OR THE FAN. misfiring.
DO NOT WEAR L O O S E CLOTHING. An engine cylinder head gasket leak can be located
between adjacent cylinders or between a cylinder and
(1) Start the engine. the adjacent water jacket.
I -8 ENGINE BR
• An engine cylinder head gasket leaking between Remove the spark plugs.
adjacent cylinders is indicated by a loss of power Remove the oil filler cap.
and/or engine misfire. Remove the air cleaner.
• An engine cylinder head gasket leaking between Calibrate the tester according to the manufactur
a cylinder and an adjacent water jacket is indicated er's instructions. The shop air source for testing
by coolant foaming or overheating and loss of coolant. should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum and 552 kPa (80 psi) recom
CYLINDER-TO-CYLINDER LEAKAGE TEST mended.
To determine i f an engine cylinder head gasket is Perform the test procedure on each cylinder accord
leaking between adjacent cylinders, follow the proce ing to the tester manufacturer's instructions. While
dures outlined in Cylinder Compression Pressure testing, listen for pressurized air escaping through
Test. An engine cylinder head gasket leaking between the throttle body, tailpipe or oil filler cap opening.
adjacent cylinders will result in approximately a Check for bubbles in the radiator coolant.
50-70% reduction in compression pressure. All gauge pressure indications should be equal,
with no more than 25% leakage.
CYLINDER-TO-WATER JACKET LEAKAGE F O R E X A M P L E : At 552 kPa (80 psi) input pres
WEST sure, a minimum of 414 kPa (60 psi) should be main
tained in the cylinder.
WARNING: USE EXTREME CAUTION WHEN THE
Refer to the Cylinder Combustion Pressure Leak
ENGINE I S OPERATING. DO NOT STAND IN A
age Test Diagnosis chart.
DIRECT LINE W I T H THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS, O R T H E F A N .
INSPECTION (ENGINE OIL LEAKS IN GENERAL) ~
DO NOT WEAR LOOSE CLOTHING.
Begin with a through visual inspection of the
Remove the radiator cap. engine, particularly at the area of the suspected leak.
Start the engine and allow i t to warm up until the I f an oil leak source. is not readily identifiable, the
engine thermostat opens. following steps should be followed:
I f a large combustion/compression pressure leak (1) Do not clean or degrease the engine at this
exists, bubbles will be visible in the coolant. time because some solvents may cause rubber to
If bubbles are not visible, install a radiator pres swell, temporarily stopping the leak.
sure tester and pressurize the coolant system. (2) Add an oil-soluble dye (use as recommended by
I f a cylinder is leaking combustion pressure into manufacturer). Start the engine and let idle for
the water jacket, the tester pointer will pulsate with approximately 15 minutes. Check the oil dipstick to
every combustion stroke of the cylinder. be sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light source.
CYLINDER COMBUSTION PRESSURE LEAKAGE (3) Using a black light, inspect the entire engine
for fluorescent dye, particularly at the suspected area
TEST .
of oil leak. I f the oil leak is found and identified,
The combustion pressure leakage test provides an
repair per service manual instructions.
accurate means for determining engine condition.
(4) I f dye is not observed, drive the vehicle at var
Combustion pressure leakage testing will detect:
ious speeds for approximately 24km (15 miles), and
• Exhaust and intake valve leaks (improper seat
repeat previous step.
ing)
(5) I f the oil leak source is not positively identified
• Leaks between adjacent cylinders or into water
at this time, proceed with the air leak detection test
jacket
method as follows:
• Any causes for combustion/compression pressure
(6) Disconnect the breather cap to air cleaner hose
loss
at the breather cap end. Cap or plug breather cap
WARNING: DO NOT REMOVE THE RADIATOR CAP nipple.
WITH THE SYSTEM HOT AND UNDER P R E S S U R E . (7) Remove the PCV valve from the cylinder head
SERIOUS BURNS FROM HOT. COOLANT CAN cover. Cap or plug the PCV valve grommet.
OCCUR. (8) Attach an air hose with pressure gauge and
regulator to the dipstick tube.
Check the coolant level and fill as required. DO
NOT install the radiator cap. CAUTION: Do not subject the engine assembly to
Start and operate the engine until i t attains nor more than 20.6 kpa (3 PSI) of test pressure.
mal ' operating temperature, then turn OFF the
(9) Gradually apply air pressure from 1 psi to 2.5
engine. '
psi maximum while applying soapy water at the sus-
BR ^ — — — — — ENGINE 9-9
pected source. Adjust the regulator to the suitable (6) For bubbles that remain steady with shaft
test pressure that provide the best bubbles which rotation, no further Inspection can be done until dis
will pinpoint the leak source. I f the oil leak is assembled. Refer to the service Diagnosis—Mechani
detected and identified, repair per service manual cal, under the Oil Leak row, for components
procedures. Inspections on possible causes and corrections.
(10) I f the leakage occurs at the rear oil seal area, (7) After the oil leak root cause and appropriate
refer to the section, Inspection for Rear Seal Area corrective action have been identified, Refer to Group
Leak. 9, Engines—Crankshaft Rear Oil Seals, for proper
(11) I f no leaks are detected, turn off the air sup replacement procedures.
ply and remove, the air hose and all plugs and caps.
Install the PCV valve and breather cap hose. Proceed HYDRAULIC TAPPETS
to next step. Before disassembling any part of the engine to cor
(12) Clean the oil off the suspect oil leak area rect tappet noise, check the oil pressure. I f vehicle
using a suitable solvent. Drive the vehicle at various has no oil pressure gauge, Install a reliable gauge at
speeds approximately 24 km (15 miles). Inspect the the pressure sending-unit. The pressure should be
engine for signs of an oil leak by using a black light. between 207-552 kPa (30-80 psi) at 3,000 RPM.
Check the oil level after the engine reaches normal
INSPECTION FOR REAR SEAL AREA LEAKS operating temperature. Allow 5 minutes to stabilize
Since i t is sometimes difficult to determine the oil level, check dipstick. The oil level in the pan
source of an oil leak in the rear seal area of the should never be above the FULL mark or below the
engine, a more Involved inspection is necessary. The ADD OIL mark on dipstick. Either of these two con
following steps should be followed to help pinpoint ditions could be responsible for noisy tappets.
the source of the leak.
I f the leakage occurs at the crankshaft rear oil seal OIL LEVEL
area:
(1) Disconnect the battery. HIGH
(2) Raise the vehicle. If oil level is above the FULL mark, i t is possible
(3) Remove torque converter or clutch housing for the connecting rods to dip Into the oil. With the
cover and inspect rear of block for evidence of oil. engine running, this condition could create foam i n
Use a black light to check for the oil leak: the oil pan. Foam in oil pan would be fed to the
(a) Circular spray pattern generally Indicates hydraulic tappets by the oil pump causing them to
seal leakage or crankshaft damage. lose length and allow valves to seat noisily.
(b) Where leakage tends to run straight down,
LOW '
possible causes are a porous block, distributor seal,
camshaft bore cup plugs, oil galley pipe plugs, oil Low oil level may allow oil pump to take in air.
filter runoff, and main bearing cap to cylinder When air is fed to the tappets, they lose length,
block mating surfaces. See Group 9, Engines, for which allows valves to seat noisily. Any leaks on
proper repair procedures of these Items. Intake side of oil pump through which air can be
(4) I f no leaks are detected, pressurized the crank drawn will create the same tappet action. Check the
case as outlined in the section, Inspection (Engine oil lubrication system from the intake strainer to the
Leaks In general) pump cover, including the relief valve retainer cap.
When tappet noise is due to aeration, i t may be
CAUTION: Do not exceed 20.6 kPa (3 psi). intermittent or constant, and usually more than one
tappet will be noisy. When oil level and leaks have
(5) I f the leak is not detected, very slowly turn the been corrected, operate the engine at fast idle. Run
crankshaft and watch for leakage. I f a leak Is engine for a sufficient time to allow all of the air
detected between the crankshaft and seal while Inside the tappets to be bled out.
slowly turning the crankshaft, i t is possible the
crankshaft seal surface Is damaged. The seal area on T A P P E T NOISE DIAGNOSIS
the crankshaft could have minor nicks or scratches (1) To determine source of tappet noise, operate
that can be polished out with emery cloth. engine at idle with cylinder head covers removed.
(2) Feel each valve spring or rocker arm to detect
CAUTION: Use extreme caution when crankshaft noisy tappet. The noisy tappet will cause the affected
polishing is necessary to remove minor nicks or spring and/or rocker arm to vibrate or feel rough in
scratches. The crankshaft seal flange Is specially operation.
machined to complement the function of the rear oil
seal.
I -11 ENGINE BR
NOTE: Worn valve guides or cocked springs are (4) The valve train generates a noise very much
sometimes mistaken for noisy tappets. If such is like a light tappet noise during normal operation.
the case, noise may be dampened by applying side Care must be taken to ensure that tappets are mak
thrust on the valve spring. If noise is not apprecia ing the noise. If more than one tappet seems to be
bly reduced, it can be assumed the noise is in the noisy, it's probably not the tappets.
tappet. Inspect the rocker arm push rod sockets
and push rod ends for wear. ENGINE OIL P R E S S U R E
(1) Remove oil pressure sending unit.
(3) Valve tappet noise ranges from light noise to a (2) Install Oil Pressure Line and Gauge Tool
heavy click. A light noise is usually caused by exces C-3292. Start engine and record pressure. Refer to
sive leak-down around the unit plunger, or by the Oil Pressure in Engine Specifications for the proper
plunger partially sticking in the tappet body cylinder. pressures.
The tappet should be replaced. A heavy click is
caused by a tappet check valve not seating, or by for
eign particles wedged between the plunger and the
tappet body. This will cause the plunger to stick in
the down position. This heavy click will be accompa
nied by excessive clearance between the valve stem
and rocker arm as valve closes. In either case, tappet
assembly should be removed for inspection and clean
ing.
rg B , _ ENGINE 9 -11
ENGINE DIAGNOSIS—GASOLINE—PERFORMANCE
ENGINE WILL NOT START 1. Weak battery. 1 . Test battery specific gravity. Charge or replace as necessary.
2 . Corroded or loose battery 2 . Clean and tighten battery connections. Apply a coat of light
connections. mineral grease to the terminals.
3. Faulty starter. 3 . Refer to Group 8A, Battery/Starter/Charging System
Diagnostics.
4. Moisture on ignition wires and 4. Wipe wires and cap clean and dry.
distributor cap.
5. Faulty ignition cables. 5. Replace any cracked or shorted cables.
6. Faulty coil or control unit. 6. Test and replace, if necessary (refer to Group 8D, Ignition
System).
7. Incorrect spark plug gap. 7 . Set gap (refer to Group 8D, Ignition System).
8. Incorrect ignition timing. 8 . Refer to Group 8D, Ignition System.
:
9. Dirt or water in fuel system. 9 . Clean system and replace fuel filter. |
10. Faulty fuel pump, relay or wiring. 1 0 . Refer to Group 14, Fuel Syster..
ENGINE STALLS OR 1. Idle speed set too low. 1. Refer to Group 14, Fuel System.
ROUGH IDLE 2 . Idle mixture too lean or too rich. 2 . Refer to Group 14, Fuel System. j
3 . Leak in intake manifold. 3 . Inspect intake manifold gasket and vacuum hoses. Replace, if
necessary (refer to Group 1 1 , Exhaust System & Intake
Manifola).
4. Install new distributor rotor.
4. Worn or burned distributor rotor.
5. Install correct wiring.
5. Incorrect ignition wiring.
6. Test and replace, if necessary (refer to Group 8D, Ignition
6. Faulty coil. System).
7 . Test and replace, if necessary (refer to Group 2 5 , Emissions
7. EGR valve leaking. Control System).
8. Incorrect cam timing. 8 . Refer to Timing Belt Service.
ENGINE LOSS OF POWER 1 . Incorrect ignition timing. 1. Refer to Group 8D, Ignition System.
2 . Worn or burned distributor rotor. 2 . Install new distributor rotor.
3 . Worn distributor shaft. 3 . Remove and repair distributor (refer to Group 8D, Ignition
System).
4. Dirty or incorrectly gapped spark 4. Clean plugs and set gap (refer to Group 8D, Ignition System).
plugs.
5. Dirt or water in fuel system. 5. Clean system and replace fuel filter. j
6. Faulty fuel pump. 6. Install new fuel pump.
7. Incorrect valve timing. 7 . Correct valve timing.
8. Blown cylinder head gasket. 8 . Install new cylinder head gasket.
9. Low compression. 9 . Test compression of each cylinder.
10. Burned, warped or pitted valves. 10. Install new valves.
11. Plugged or restricted exhaust 1 1 . Install new parts, as necessary.
system. 1 2 . Replace any cracked or shorted cables. }
1 2 . Faulty ignition cables. 13. Test and replace, as necessary (refer to Group 8D, Ignition
1 3 . Faulty coil. System).
14. Incorrect cam timing. 14. Refer to Timing Belt Service.
ENGINE MISSES O N 1 . Dirty or gap set too wide in spark 1 . Clean spark plugs and set gap (refer to Group 8D, Ignition
ACCELERATION System).
2. Incorrect ignition timing. 2 . Refer to Group 8D, Ignition System.
3. Dirt in fuel system. 3 . Clean fuel system.
4. Burned, warped or pitted valves. 4. Install new valves.
5. Faulty coil. 5. Test and replace, if necessary, (refer to Group 8D, Ignition
6. Incorrect cam timing. System).
6. Refer to Timing Belt Service.
ENGINE MISSES AT HIGH 1 . Dirty or gap set too wide in spark 1. Clean spark plugs and set gap (refer to Group 8D, Ignition
SPEED plug. System).
2 . Worn distributor shaft. 2 . Remove and repair distributor (refer to Group 8D, Ignition
System).
3. Worn or burned distributor rotor. 3 . Install new distributor rotor.
4. Faulty coil. 4. Test and replace, as necessary (refer to Group 8D, Ignition
5. Incorrect ignition timing. System).
6. Dirty injector in throttle body. 5. Refer to Group 8D, Ignition System.
7. Dirt or water in fuel system. 6. Clean injector.
8. Incorrect cam timing. 7. Clean system and replace fuel filter.
8 . Refer to Timing Belt Service. j
9309-227
9 -12 ENGINE ______— __________ BR
ENGINE DIAGNOSIS—GASOLINE—MECHANICAL
NOISY VALVES 1. High or low oil level in crankcase. 1. Check for correct oil level (refer to
Group 0, Lubrication and Maintenance.
2. Thin or diluted oil. 2. Change oil (refer to Group 0,
Lubrication and Maintenance).
3. Low oil pressure. 3. Check engine oil level.
4. Dirt in tappets/lash adjusters. 4. Clean hydraulic tappets/hydraulic
lash adjusters.
5. Bent push rods. 5. Install new push rods.
6. Worn rocker arms. 6. Inspect oil supply to rocker arms.
7. Worn tappets/lash adjusters. 7. Install new hydraulic tappets/
hydraulic lash adjusters.
8. Worn valve guides. 8. Ream and install new valves with
oversize stems.
9. Excessive runout of valve seats 9. Grind valve seats and valves.
on valve faces.
CONNECTING ROD NOISE 1. Insufficient oil supply. 1. Check engine oil level (refer to
Group 0, Lubrication and Maintenance).
2. Low oil pressure. 2. Check engine oil level. Inspect oil
pump relief valve and spring.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
4. Excessive bearing clearance. 4. Measure bearings for correct
clearance. Repair as necessary.
5. Connecting rod journal out-of- 5. Replace crankshaft or grind journals.
round.
6. Misaligned connecting rods. 6. Replace bent connecting rods.
MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level (refer to
Group 0, Lubrication and Maintenance).
2. Low oil pressure. 2. Check engine oil level. Inspect oil
pump relief valve and spring.
4. Excessive bearing clearance. 4. Measure bearings for correct
clearance. Repair as necessary.
5. Excessive end play. 5. Check No. 3 main bearing for wear
on flanges.
6. Crankshaft journal out-of-round, 6. Grind journals or replace crankshaft.
worn.
7. Loose flywheel or torque converter. 7. Tighten to correct torque.
J9509-62
BR - — - — — ENGINE 9 -13
SERVICE DIAGNOSIS—GASOLINE—LUBRICATION
CONDITION POSSIBLE CAUSED CORRECTION
OIL LEAKS 1. Gaskets and O-Rings. 1.

(a) Misaligned, deteriorated or torn. (a) Replace the part.
(b) Loose fastener, broken or porous (b) Tighten, repair or replace the part.
metal part.
2. Crankshaft Rear Seal 2.
(a) Misinstalled, inverted or torn lip (a) Replace the seal.
(b) Torn, cut or shaved seal back bead. (b) Replace the seal.
3. Crankshaft Seal Flange. 3.
Scratched, nicked or grooved. Replace or polish if necessary.
4. Cylinder block to Cap Mating Surface. 4.
(a) Inadequate Loctite sealant. (a) Apply sealant per sealant per service
manual.
(b) Oil hole burr. (b) Carefully stone or chamfer hole.
5. Oil Pan to Rear Main Cap Sealant 5.
(Slots 3.9 - 5.2 only).
(a) inadequate or mislocated sealant. (a) Apply sealant per service manual
procedures.
(b) Torn, cut or misinstalled oil pan. (b) Replace the gasket.
(c) Cracked or damaged oil pan flange. (c) Replace the oil pan.
6. Chain Case Cover Seal. 6.
(a) Misinstalled, cocked or misaligned. (a) Replace per service manual procedures.
(b) Torn, cut or damaged seal lips. (b) Replace the seal.
(c) Scratched or damaged seal casing (c) Replace the seal.
or cover bore.
(d) Scratched or damaged vibration (d) Minor damage can be polished out;
damper hub. otherwise replace the part.
OIL PRESSURE DROP 1. Low oil level. 1. Check engine oil level.
2. Faulty oil pressure sending unit. 2. Install new sending unit.
3. Low oil pressure. 3. Check sending unit and check main bearing
oil clearance.
4. Clogged oil filter. 4. Install new oil filter.
5. Worn parts in oil pump. 5. Replace worn parts or pump.
7. Excessive bearing clearance. 7. Measure bearings for correct clearance.
8. Oil pump relief valve stuck. 8. Remove valve and inspect, clean and install.
9. Oil pump suction tube loose bent or
; 9. Remove oil pan and install new tube, if
cracked. necessary.
10. Oil pump cover warped or cracked. 10. Install new oil pump.
OIL PUMPING AT RINGS; 1. Worn, scuffed or broken rings. 1. Hone cylinder bores and install new rings.
SPARK PLUGS FOULING 2. Carbon in oil ring slot. 2. Install new rings.
3. Rings fitted too tightly in grooves. 3. Remove the rings. Check grooves. If
grooves are not proper width, replace piston.
4. Worn valve guides. 4. Ream guides and replace valves with
oversize valves and seals.
5. Leaking intake gasket (3.9L & 5. Replace gasket and tighten intake manifold
5.2L engines). to proper torque.
6. Leaking valve guide seals (3.9L & 6. Replace seals.
5.2L engines).
7. Dislodged valve guide seals (3.9L & 7 Seat valve guide seals or replace, as
5.2L engines). n e e d e d
J9509-61
9 -14 ENGINE — — - — — BR
SERVICE DIAGNOSIS—DIESEL—PERFORMANCE

ENGINE WILL NOT CRANK 1. Starting motor operating, but 1. Remove the starter motor. Check for
OR CRANKS SLOWLY not cranking the engine. broken flywheel teeth or a broken
starting motor spring.
2. Crankshaft rotation restricted. 2. Rotate the engine to check for rotational
resistance.
3. Starting circuit connections 3. Clean and tighten connections.
loose or corroded.
4. Neutral safety switch or starter 4. Check starter relay supply voltage and
relay inoperative. proper operation of neutral safety switch
if equipped. Replace defective parts.
5. Battery charge low. 5. Check battery voltage. Replace battery
if a charge cannot be held.
6. No voltage to starter solenoid. 6. Check voltage to solenoid. If necessary,
replace the solenoid.
7. Solenoid or starter motor 7. Replace starter motor.
inoperative.
ENGINE CRANKS, BUT 1. No fuel in supply tank. 1. Fill fuel supply.
WILL NOT S T A R T - 2. Electrical fuel shutdown 2. Check for loose wires and verify that the
NO SMOKE FROM solenoid not operating. fuel shutdown solenoid and fuel
EXHAUST shutdown solenoid relay are functioning.
3. Air intake or exhaust plugged. 3. Remove the obstruction.
4. Fuel filter plugged. 4. Drain fuel/water separator and replace
fuel filter.
5. Excessive fuel inlet restriction. 5. Check fuel inlet restriction. Correct
cause.
6. Injection pump not getting fuel 6. Check fuel flow/bleed fuel system.
or fuel is aerated.
7. Inoperative fuel transfer (Lift) 7. Check fuel line for restrictions and fue
pump. pressure.
8. One or more injectors worn or 8. Check/replace bad or improperly
not operating properly. operating injectors.
9. Worn or inoperative injection 9. Visually check delivery with externally
pump. connected injector to one of the pump
outlets. Repair or replace the pump if
fuel is not being delivered.
10. Internal pump timing incorrect. 10. Time the pump (refer to Group 14, Fuel
System).
11. Camshaft out of time. 11. Check/correct gear train timing
alignment.
J9509-145
BR— — — ENGINE 9-15
SERVICE DIAGNOSIS—DIESEL—PERFORMANCE—CONT.
ENGINE HARD TO START, 1. Incorrect starting procedure. 1 . The fuel shutoff solenoid control must
OR WILL NOT S T A R T - be in the run position. Ensure proper
SMOKE FROM EXHAUST procedure is being used.
2. Cranking speed too slow. 2. A. Verify that the transmission is not
engaged.
B. Check the battery, starting motor and
look for loose or corroded wiring
connections.
C. Rotate the engine with barring tool
(Snap-on Tool SP371, MTE No.
3377462, or equivalent) to check for
external rotational resistance.
3. Intake heater system not 3. Verify system is working. Repair/replace
working. inoperative parts.
4. Insufficient intake air. 4. Inspect or replace filter and check for
obstructions to the air supply tube.
5. Air in fuel system or the fuel 5. Check the flow through the filter and
supply is inadequate. bleed the system. Locate and eliminate
the air source.
6. Fuel transfer (lift) pump. 6. Measure transfer pump outlet pressure.
If needed, repair or replace pump.
7. Injection pump throttle linkage 7. Visually check the linkage.
loose or damaged. Adjust/replace linkage.
8. Contaminated fuel. 8. Verify by operating the engine with
clean fuel from a temporary tank. Check
for presence of gasoline. Drain and
flush fuel supply tank. Replace
fuel/water separator filter.
9. Fuel screen plugged. 9. Check fuel screen.
10. One or more injectors worn or 10. Check/replace improperly operating
not operating properly. injectors.
11. Worn or inoperative injection 11. Visually check fuel delivery with an
pump. externally connected injector to one of
the pump outlets. Repair or replace the
pump if fuel is not being delivered.
12. Injection pump out of time. 12. Check/Time the pump (refer to Group
14, Fuel System).
13. Valves incorrectly adjusted. 13. Adjust valves.
14. Engine compression low. 14. Check compression to identify the
problem.
J9509-146
9 -16 ENGINE — BR
ENGINE STARTS, BUT WILL 1. Idle speed too low for the 1 Adjust the idle speed.
NOT KEEP RUNNING accessories.
2. Intake air or exhaust system 2. Visually check for exhaust restriction and
restricted. inspect the air intake. Repair/replace
restricting parts.
3. Air in the fuel system or the fuel 3. Check flow through the filter and bleed
supply is inadequate. the system. Locate and eliminate the air
source.
4. Fuel waxing due to extremely 4. Verify by inspecting the fuel filter. Clean
cold weather. the system and use climatized fuel.
Replace fuel/water separator filter. Check
fuel heater for proper operation.
5. Contaminated fuel. 5. Verify by operating the engine with clean
fuel from a temporary supply tank. Check
for presence of gasoline. Replace
SURGING (SPEED 1. If the condition occurs at idle, 1. Adjust the idle speed.
CHANGE) the idle speed is set too low for
the accessories.
2. Improperly operating injection 2. Replace the injector pump.
pump.
ROUGH IDLE 1. If engine is cold, intake heater 1. Refer to intake heater system (see Group
(IRREGULARLY FIRING OR system defective. 14, Fuel System).
ENGINE SHAKING) 2. Adjust idle speed.
2. Idle speed too low for the
accessories. 3. Repair or replace mounts.
3. Engine mounts damaged or
lose. 4. Correct leaks in the high pressure lines
4. High pressure fuel leaks. fittings or delivery valves.
5. Bleed the fuel system and eliminate the j
5. Air in the fuel system. source of the air.
6. Check and replace the injector with the
6. Sticking needle valve in an sticking needle valve.
injector.
ENGINE RUNS ROUGH 1. Fuel injection lines leaking. 1. Correct leaks in the high pressure lines,
fittings, injectors sealing washers or
delivery valves.
2. Air in the fuel or the fuel supply 2. Check the flow through the filter and
is inadequate. bleed the system. Locate and eliminate
the air source.
3. Contaminated fuel. 3. Verify by operating the engine with clean
fuel from a temporary supply tank. Check
for presence of gasoline. Replace
J9509-147
BR ENGINE 9 -17

ENGINE RUNS ROUGH 4. Incorrect valve operation. 4. Check for a bent push rod and adjust
CONT. valves. Replace push rod, if necessary.
5. Injection pump timing incorrect. 5. Check/time pump (refer to Group 14,
Fuel System).
6. Improperly operating injectors. 6. Replace inoperative injectors.
7. Defective injection pump 7. Repair or replace injection pump.
(delivery valve).
8. Camshaft out of time. 8. Check/correct gear train timing
alignment,
9. Damaged camshaft or tappets. 9. Inspect camshaft valve lift. Replace
camshaft and tappets.
ENGINE RPM WILL NOT 1. Engine overload. 1. Verify high idle speed without load.
REACH RATED SPEED Investigate operation to be sure correct
gear is being used.
2. Improperly operating 2. Verify engine speed with hand
tachometer. tachometer, correct as required.
3. Throttle linkage worn or 3. Adjust linkage for stop-to-stop fuel
incorrectly adjusted. control lever travel. Replace linkage if
necessary.
4. Inadequate fuel supply. 4. Check the fuel flow through the system
• to locate the reason for inadequate fuel
supply, correct as required.
5. Air/fuel controls leak. 5. Check and repair leak. Check AFC
tubing for obstruction.
6. Improperly operating injection 6. Repair or replace injection pump.
pump.
LOW POWER 1. Fuel control lever not moving 1. Check/correct for stop-to-stop travel.
to full throttle.
2. High oil level. 2. Check/correct oil level.
3. Engine overloaded. 3. Check for added loading from
accessories or driven units, brakes
dragging and other changes in vehicle
loading. Repair/replace as needed.
4. Slow throttle response caused 4. Check for leaks and obstructions.
by leaking or obstructed air Tighten the fittings. Repair or replace
control tube or improperly the pump if the controls are not
operating control in the pump. functioning.
5. Inadequate intake air flow. 5. Inspect/replace air cleaner element.
Look for other restrictions.
6. Inadequate fuel supply. Air in 6. Inspect/correct leaks in the high
the fuel. pressure lines, fittings injectors sealing
washers or delivery valve seals.
7. Excessive exhaust restriction. 7. Check/correct the restriction in the
exhaust system.
J9509-148
9 -18 ENGINE . ~ BR
S E R V I C E DIAGNOSIS—DIESEL—PERFORMANCE—CONT.
LOW POWER CONT. 8. High fuel temperature. 8. Verify that fuel heater is off when engine
is warm. Check for restricted fuel drain
tube. Repair/replace as needed.
9. Poor quality fuel or fuel 9. Verify by operating from a temporary
contaminated with gasoline. tank with good fuel. Check for presence
of gasoline. Replace fuel/water
separator filter.
10. Air leak between the 10. Check/correct leaks in hoses, gaskets,
turbocharger and the intake charge air cooler and around mounting
manifold. capscrews or through holes in the
manifold cover.
11. Exhaust leak at the manifold or 11. Check/correct leaks in the manifold or
turbocharger. turbocharger gaskets. If manifold is
cracked, replace manifold.
12. Improperly operating 12. Inspect/replace turbocharger.
turbocharger.
13. Wastegate operation. 13. Check waste gate operation.
14. Valve not operating. 14. Check for bent push rod, replace if
necessary.
15. Worn or improperly operating 15. Check/replace injectors.
injectors.
16. Incorrect injection pump timing. 16. Verify injection pump timing (see Group
14, Fuel System).
17. Improperly operating injection 17. Repair or replace injection pump.
pump.
E X C E S S I V E EXHAUST 1 Engine running too cold (white 1. Refer to troubleshooting for coolant
SMOKE smoke). temperature below normal (refer to
Group 7, Cooling System). Inspect
intake manifold heater system for
proper operation.
2 Improper starting procedure 2. Use proper starting procedures.
(white smoke).
3 Fuel supply inadequate. 3. Check fuel supply pressure and inlet
restriction.
4 Injection pump timing. 4 Check and time pump (refer to Group
14, Fuel System).
5 Inadequate intake air. • 5 Inspect/change air filter. Look for other
restriction. Check charge air cooler for
obstructions.
6 Air leak between turbocharger 6 Check/correct leaks in the air crossover
and intake manifold. tube, hoses, gaskets, mounting
capscrews or through holes in the
manifold cover.
7 Exhaust leak at the manifold or 7 Check/correct leaks in the manifold or
turbocharger. turbocharger gaskets. If cracked,
replace manifold.
8 . Improperly operating 8 Inspect/replace turbocharger.
turbocharger.
9 . Improperly operating injectors. 9 Check and replace inoperative injectors.
J9509-149
BR — ENGINE 9 - 19
EXCESSIVE EXHAUST 10. improperly operating or 10. Repair or replace injection pump.
SMOKE CONT. overfueled injector pump.
11. Piston rings not sealing (blue 11. Perform blow-by check. Correct as
smoke). required.
ENGINE WILL NOT SHUT 1. Fuel shutoff solenoid or 1. Check/replace fuel shutoff solenoid or
OFF solenoid relay inoperative. relay.
2. Engine running on fumes 2. Check the air intake ducts for the source
drawn into the air intake. of fumes.
WARNING: In case of engine runaway
due to flammable fumes from gasoline
spills or turbocharger oil leaks being
sucked into the engine. Shut off engine
ignition switch first then use a C02 fire
extinguisher and direct the spray under
the front bumper to remove oxygen
supply. The engine air intake is on the
passenger side behind the bumper. The
fire extinguisher must be directed at this
location for emergency shutdown
conditions.
3. Fuel injection pump 3. Repair or replace fuel injection pump.
malfunction.
COOLANT TEMPERATURE 1. Low coolant level. 1. Check coolant level. Add coolant, if
ABOVE NORMAL necessary. Locate and correct the
source of the coolant loss, (refer to
Group 7, Cooling).
2. Incorrect/improperly operating 2. Replace cap with the correct rating for
pressure cap. the system.
3. Loose drive belt on water 3. Check/replace belt or belt tensioner.
pump/fan.
4. Inadequate air flow to the 4. Check/repair radiator core, fan shroud
radiator. and viscous fan drive as required.
5. Radiator fins plugged. 5. Blow debris from fins.
6. Collapsed radiator hose. 6. Replace the hose. Check cap operation,
(refer to Group 7, Cooling System).
7. Improperly operating 7. Verify that the gauge and temperature
temperature sensor/gauge. sensor are accurate. Replace
gauge/sensor, if bad.
8. Improperly operating, incorrect 8. Check and replace the thermostat.
or no thermostat.
9. Air in the cooling system. 9. A. Make sure the fill rate is not being
exceeded and the correct vented
thermostat is installed.
B. Check for loose hose clamps.
Tighten if loose.
C. If aeration continued, check for a
compression leak through the head
gasket.
J9509-150
9 - 20 ENGINE — — BR
COOLANT TEMPERATURE 10. Inoperative water pump. 10. Check and replace the water pump.
ABOVE NORMAL CONT. 11. Incorrect injection pump timing. 11. Check/time the injector pump (refer to
Group 14, Fuel System). ,
12. Overfueied injection pump. 12. Repair or replace the injection pump.
13. Plugged cooling passages in 13. Flush the system and fill with clean
radiator, head, head gasket or coolant.
block.
14. Engine overloaded. 14. Verify that the engine load rating is nci
being exceeded.
COOLANT TEMPERATURE 1. Too much air flow across the 1. Check/repair viscous fan drive as
BELOW NORMAL radiator. required.
2. Incorrect thermostat or 2. Check and replace thermostat.
contamination in thermostat.
3. Temperature sensor or gauge 3. Verify that the gauge and sensor are
inoperative. accurate. If not, replace gauge/sensor.
4. Coolant not flowing by 4. Check and clean coolant passages.
temperature sensor.
J9509-151
BR — ENGINE 9 - 21
D I A G N O S I S AidID T E S T I N G (Continued)
SERVICE DIAGNOSIS—ilESE L—MECHANIC-

LUBRICATING OIL 1. Low oil level. 1. A. Check and fill with clean engine
PRESSURE LOW B. Check for a severe external oil leak
that could reduce the pressure.
2. Oil viscosity thin, diluted or 2. Verify the correct oil is being used. j
wrong specification. Check for oil dilution. Refer to 1
Contaminated Lube Oil (Engine \
Diagnosis Mechanical). 1
3. Improperly operating pressure 3. Verify the pressure switch is functioning j
switch/gauge. correctly. If not, replace switch/gauge \
4. Relief valve stuck open. 4. Check/replace valve. j
5. Plugged oil filter. 5. Change oil filter. Oil filter change |
interval may need to be revised. \
6. If cooler was replaced, 6. Check/remove shipping plugs. \
shipping plugs left in cooler.
7. Worn oil pump. ' 7. Check and replace oil pump.
8. Suction tube loose or seal 8. Check and replace seal.
leaking.
9. Loose main bearing cap. 9. Check and install new bearing and j
tighten cap to proper torque. \
10. Worn bearings or wrong 10. Inspect and replace connecting rod or
bearings installed. main bearings. Check and replace
piston cooling nozzles.
11. Oil jet under piston bad fit into 11. Check oil jet position. j
main carrier.
LUBRICATING OIL 1. Pressure switch/gauge not 1. Verify the pressure switch is functioning
PRESSURE TOO HIGH operating properly. correctly. If not, replace switch/gauge.
2. Engine running to cold. 2. Refer to Coolant Temperature Below
Normal (Engine Diagnosis Performance). j
3. Oil viscosity too thick. 3. Make sure the correct oil being used, j
(Refer to Group 0, Lubrication and j
Maintenance). \
4. Oil pressure relief valve stuck 4. Check and replace valve.
closed or binding.
LUBRICATING OIL LOSS 1 . External leaks. 1. Visually inspect for oil leaks. Repair as |
required. \
2. Crankcase being overfilled. 2. Verify that the correct dipstick is being used. X
3. Incorrect oil specification or 3. A. Make sure the correct oil is being \
viscosity. used. j
B. Look for reduced viscosity from j
dilution with fuel. j
C. Review/reduce the oil change j
intervals. ;
4. Oil cooler leak. 4. Check and replace the oil cooler.
5. High blow-by forcing oil out the 5. Check the breather tube area for signs ' .
breather. oil loss. Perform the required repairs. j
6. Turbocharger leaking oil to the 6. Inspect the air ducts for evidence of oil
air intake. transfer. Repair as required. ' ;
7. Piston rings not sealing (oil 7. Perform blow-by check. Repair as
being consumed by the engine). required. j
JS509-152
9 - 22 ENGINE — _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . _ BR
SERVICE Di&GNOSiS—DIESEL—MECHANICAL—CONT.
CONDITION POSSIBLE C A U S E S CORRECTION
COMPRESSION KNOCKS. 1. Air in the fuel system. 1. Bleed the fuel system (refer to Group 14,
Fuel System).
2. Poor quality fuel or water/ 2. Verify by operating from a temporary tank
gasoline contaminated fuel. with good fuel. Clean and flush the fuel
supply tanks. Replace fuel/water
separator filter.
3. Engine overloaded. 3. Verify the engine load rating is not being
exceeded.
4. Incorrect injection pump timing. 4. Check and time injection pump (refer to
Group 14, Fuel System).
5. Improperly operating injectors. 5. Check and replace inoperative injectors.
E X C E S S I V E VIBRATION 1. Loose or broken engine mounts. 1. Replace engine mounts.

2. Damaged fan or improperly 2. Check and replace the vibrating
operating accessories. components.
3. Improperly operating vibration
damper. 3. Inspect/replace the vibration damper.
4. Improperly operating viscous fan
drive. 4. Inspect/replace the fan drive.
, 5. Worn or damaged generator
bearing. 5. Check/replace the generator.
6. Flywheel housing misaligned.
6. Check/correct flywheel alignment.
7. Loose or broken power
component. 7. Inspect the crankshaft and rods for
damage that causes an unbalance,
repair/replace as required.
8. Worn or unbalanced driveline 8. Check/repair driveline components.
components.
E X C E S S I V E ENGINE 1. Drive belt squeal, insufficient 1. Check the automatic tensioner and
NOISES tension or abnormally high inspect the drive belt. Make sure water
loading. pump, tensioner pulley, fan hub and
generator turn freely.
2. Intake air or exhaust leaks. 2. Refer to Excessive Exhaust smoke
(Engine Diagnosis Performance).
3. Excessive valve lash. 3. Adjust valves. Make sure the push rods
are not bent and rocker levers or
adjusting screws are not severely worn.
Replace bent or severely worn pads.
4. Turbocharger noise. 4. Check turbocharger impeller and turbine
wheel for housing contact. Repair/replace
as required.
5. Gear train noise. 5. Visually inspect and measure gear
backlash. Replace gears as required.
6. Power function knock. 6. Check/replace rod and main bearings.
GENERATOR NOT 1. Loose or corroded battery. 1. Clean/tighten battery connection. |
CHARGING OR 2. Generator belt slipping. 2. Check/replace automatic belt tensione
INSUFFICIENT CHARGING Check/replace drive belt.
3. Generator pulley loose on shaft. 3. Tighten pulley.
4. Improperly operating generator. 4. Check/replace generator.
J9509-153
BR 3.9L ENGINE 9 - 23
3.91 ENGINE
INDEX
page page
GENERAL INFORMATION ENGINE FRONT MOUNTS 29

OIL PUMP PRESSURE 23 ENGINE REAR MOUNT 30
PISTON AND CONNECTING ROD ASSEMBLY . . 23 FRONT CRANKSHAFT OIL SEAL 42
VALVES AND VALVE SPRINGS 23 HYDRAULIC TAPPETS 34
DESCRIPTION AND OPERATION OIL PAN 40
ENGINE COMPONENTS 26 OIL PUMP 41
ENGINE DESCRIPTION 23 PISTON AND CONNECTING ROD ASSEMBLY . . 41
ENGINE LUBRICATION SYSTEM 24 TIMING CHAIN COVER 36
SERVICE PROCEDURES TIMING CHAIN 38
CONNECTING ROD BEARINGS 28 VALVES AND VALVE SPRINGS—CYLINDER
CRANKSHAFT MAIN BEARINGS 29 HEAD REMOVED 34
CRANKSHAFT 29 VIBRATION DAMPER 36
FITTING PISTONS 27 DISASSEMBLY AND ASSEMBLY
FITTING RINGS 27 CYLINDER BLOCK 48
TIMING CHAIN STRETCH 27 HYDRAULIC TAPPETS 45
VALVE TIMING 26 OIL PUMP 48
REMOVAL AND INSTALLATION VALVES, GUIDES AND SPRINGS 46
CAMSHAFT BEARINGS 39 CLEANING AND INSPECTION
CAMSHAFT 38 CRANKSHAFT INSPECTION OF JOURNALS . . . 49
CRANKSHAFT MAIN BEARINGS 39 CYLINDER BLOCK 51
CRANKSHAFT REAR OIL SEALS 43 CYLINDER HEAD COVER 48
CRANKSHAFT 41 CYLINDER HEAD 48
CYLINDER HEAD COMPONENTS—IN VEHICLE OIL PAN 51
SERVICE 32 OIL PUMP 49
CYLINDER HEAD COVER 32 PISTON AND CONNECTING ROD INSPECTION . 49
CYLINDER HEADS 33 SPECIFICATIONS
DISTRIBUTOR DRIVE SHAFT BUSHING 35 ENGINE SPECIFICATIONS 52
ENGINE ASSEMBLY 30 SPECIAL TOOLS
ENGINE CORE OIL AND CAMSHAFT PLUGS . . 45 3.9L ENGINE 56
GENERAL INFORMATION across the thrust face. This allows for expansion
under normal operating conditions. Under operating
VALVES AND VALVE SPRINGS temperatures, expansion forces the pin bosses away
The valves are arranged in-line and are inclined from each other, causing the piston to assume a more
18°. The rocker pivot support and the valve guides nearly round shape.
are cast integral with the heads. All pistons are machined to the same weight,
regardless of size, to maintain piston balance.
OIL PUMP PRESSURE The piston pin rotates in the piston only and is
The MINIMUM oil pump pressure is 41.4 kPa (6 retained by the press interference fit of the piston
psi) at curb idle. The MAXIMUM oil pump pressure pin in the connecting rod.
is 207-552 kPa (30-80 psi) at 3,000 RPM or more.
CAUTION: If oil pressure is ZERO at curb idle, DO
NOT run engine at 3,000 RPM.
ENGINE DESCRIPTION
The 3.9 Liter (238 CID) six-cylinder engine is a
PISTON AND CONNECTING ROD ASSEMBLY V-Type, lightweight, single cam, overhead valve
The pistons are elliptically turned so that the engine with hydraulic roller tappets (Fig. 1).
diameter at the pin boss is less than its diameter This engine is designed to use unleaded fuel.
I - 24 3 J L ENGINE — — BR
D E S C R I P T I O N AMD OPERATION (Continued)
X m 3.9L T XXXX XXXXXXXX

Engine Type 90° V-6 OHV
Bore and Stroke .99.3 x 84.0 mm (3.91 x 3.31 in.)
Displacement.................................. 3.9L (238 eu. in.) X = Last Digit of Model Year
Compression Ratio ....9.1:1 M = Plant - M Mound Road
Torque 312 N * m (230 ft. lbs.) O 3,200 rpm S Saltillo
Firing Order 1-6-5-4-3-2 T Trenton
lubrication .....Pressure Feed - Full Flow Filtration K Toluca
Engine Oil Capacity 3.8L (4.0 Qts) with Filter 3.9L = Engine Displacement
Cooling System Liquid Cooled - Forced Circulation T = Usage - T Truck
Cooling Capacity. 14.3L (15.1 Qts) XXXX = Month/Day
Cylinder Block... Cast Iron
XXXXXXXX = Serial Code - Last 8 Digits of VIN No.
Crankshaft........................................................Nodular Iron
Cylinder Head ...Cast Iron
J9209-72
Combustion Chambers "Fast Bum" Design
Camshaft. ..Nodular Cast Iron Fig. 3 Engine Identification Number
Pistons..............................................Aluminum Alloy w/Struf
Connecting Rods Forged Steel
cap. The pump draws oil through the screen and
inlet tube from the sump at the rear of the oil pan.
The oil is driven between the drive and idler gears
J9409-9 and pump body, then forced through the outlet to the
Fig. 1 Engine Description block. An oil gallery in the block channels the oil to
Engine lubrication system consists of a rotor type the inlet side of the full flow oil filter. After passing
oil pump and a full-flow oil filter. through the filter element, the oil passes from the
The cylinders are numbered from front to rear; 1, center outlet of the filter through an oil gallery that
3, 5 on the left bank and 2, 4, 6 on the right bank. channels the oil up to the main gallery, which
The firing order is 1-6-5-4-3-2 (Fig. 2). extends the entire length on the right side of the
block. The oil then goes down to the No. 1 main bear
ing, back up to the left side of the block, and into the
oil gallery on the left side of the engine.
Galleries extend downward from the main oil gal
lery to the upper shell of each. main bearing. The
crankshaft is drilled internally to pass oil from the
main bearing journals to the connecting rod journals.
Each connecting rod bearing has half a hole i n it, oil
passes through the hole when the rods rotate and the
hole lines up, oil is then thrown off as the rod
rotates. This oil - throwoff lubricates the camshaft
lobes, distributor drive gear, cylinder walls, and pis
ton pins.
The hydraulic valve tappets receive oil directly
from the main oil gallery. The camshaft bearings
J9309-26
receive oil from the main bearing galleries. The front
camshaft bearing journal passes oil through the cam
Fig. 2 Firing Order shaft sprocket to the timing chain. Oil drains back to
The engine serial number is stamped into a the oil pan under the No. 1 main bearing cap.
machined pad located on the left front corner of the The oil supply for the rocker arms and bridged
cylinder block. When component part replacement is pivot assemblies is provided by the hydraulic valve
necessary, use the engine type and serial number for tappets, which pass oil through hollow push rods to a
reference (Fig. 3). hole in the corresponding rocker arm. Oil from the
rocker arm lubricates the valve train components.
ENGINE LUBRICATION SYSTEM The oil then passes down through the push rod guide
A gear-type positive displacement pump is holes and the oil drain-back passages in the cylinder
mounted at the underside of the rear main bearing head, past the valve tappet area, and then returns to
the oil pan.
O
m
BOLT W
OIL D E F L E C T O R R O C K E R ARM 0
TAB PIVOT R O C K E R ARM 30
ROCKER 1
OIL SUPPLY ARM
FROM HOLLOW TO MAIN
PUSH ROD BEARINGS
DRIP OILING HOLLOW
FOR VALVE TIP PUSH ROD
O
m
CYLINDER HEAD
BOSS TAPPET 30
OIL SUPPLY VIA
HOLLOW PUSH ROD 3
SUPPLY IS FROM OIL
G A L L E R Y M E T E R E D THROUGH
HYDRAULIC TAPPET o
o
3
OIL PASSAGE FOR OIL
P R E S S U R E INDICATOR LIGHT
5'
c
RIGHT OIL G A L L E R Y a.
PASSAGE
TO CAMSHAFT
REAR BEARING
OIL FROM FILTER TO CONNECTING

PLUG TO S Y S T E M ROD BEARINGS
OIL TO FILTER OIL INTAKE
FROM OIL PUMP OIL FILTER
CRANKSHAFT
Fig. 4 Oil Lubrication System

I - 26 3.9L ENGINE BR
DESCRIPTION Mm O P E R A T I O N (Continued)
ENGINE COMPONENTS CRANKSHAFT
A crankshaft that has undersize journals is
CYLINDER HEAD CQWBP* stamped with 1/4 inch letters near the notch of the
A steel-backed silicone gasket.is used with the cyl No. 6 crankshaft counterweight.
inder head cover. This gasket is reuseable. F O R E X A M P L E : R2 stamped on the No. 6 crank
shaft counterweight indicates that the No.2 rod jour
CYLINDER HEADS nal is 0.025 mm (0.001 in) undersize. M4 indicates
The alloy cast iron cylinder heads are held in place that the No. 4 main journal is 0.025 mm (0.001 in)
by eight bolts. The spark plugs are located in at peak undersize. R3 M2 indicates that the No. 3 rod journal
of the wedge between the valves (Fig. 5). and the No. 2 main journal are both 0.025 mm (0.001
in) undersize.
SPARK SPARK INTAKE
PLUGS PLUG VALVE
When a crankshaft is replaced, all main and con
necting rod bearings, should be replaced with new
bearings. Therefore, selective fitting of the bearings
is not required when a crankshaft and bearings are
replaced.
CRANKSHAFT MAIN BEARINGS

Bearing caps are NOT interchangeable and should
be marked at removal to ensure correct assembly.
Upper and lower bearing halves are NOT inter
changeable. Lower main bearing halves of No.l and 3
are interchangeable.
Upper and lower No. 2 bearing halves are flanged
EXHAUST INTAKE EXHAUST to carry the crankshaft thrust loads. They are NOT
VAIVE VALVES VALVES J9309-35
interchangeable with any other bearing halves i n the
engine. Bearing shells are available in standard and
Fig. 5 Cylinder Head Assembly the following undersizes: 0.25 mm (0.001 in.), 0.051
VALVES AND VALVE SPRINGS mm (0.002 in.), 0.076 mm (0.003 in.), 0.254 mm
The valves are arranged in-line and inclined 18°. (0.010 in.) and 0.305 mm (0.012 in.). Never install an
The rocker pivot support and the valve guides are undersize bearing that will reduce clearance below
cast integral with the heads. specifications.
OIL PUMP CRANKSHAFT REAR OIL SEALS

The service seal is a two piece, Viton seal. The
OIL PUMP PRESSURE upper seal half can be installed with crankshaft
The MINIMUM oii pump pressure is 41.4 kPa (6 removed from engine or with crankshaft installed.
psi) at curb idle. The MAXIMUM oil pump pressure When a new upper seal is installed, install a new
is 207-552 kPa (30-80 psi) at 3,000 RPM or more. lower seal. The lower seal half can be installed only
with the rear main bearing cap removed.
CAUTION; If oil pressure is Z E R O at curb idle, DO
SERVICE PROCEDURES
PISTON AND CONNECTING ROD ASSEMBLY VALVE TIMING

The pistons are elliptically turned so that the (1) Turn crankshaft until the No. 6 exhaust valve
diameter at the pin boss is less than its diameter is closing and No. 6 intake valve is opening.
across the thrust face. This allows for expansion (2) Insert a 6.350 mm (1/4 in.) spacer between
under normal operating conditions. Under operating rocker arm pad and stem tip of No. 1 intake valve.
temperatures, expansion forces the pin bosses away Allow spring load to bleed tappet down giving, in
from each other, causing the piston to assume a more effect, a solid tappet.
nearly round shape. (3) Install a dial indicator so plunger contacts
All pistons are machined to the same weight, valve spring retainer as nearly perpendicular as pos
regardless of size, to maintain piston balance. sible. Zero the indicator.
The piston pin rotates in t h e piston only and is (4) Rotate the crankshaft clockwise (normal run
retained by the press interference fit of the piston ning direction) until the valve has lifted 0.254 mm
pin in the connecting rod. (0.010 inch). The timing of the crankshaft should
now read from 10° before top dead center to 2° after Piston diameter should be measured at the top of
top dead center. Remove spacer. skirt, 90° to piston pin axis. Cylinder bores should be
measured halfway down the cylinder bore and trans
CAUTION; DO NOT turn crankshaft any further verse to the engine crankshaft center line.
clockwise, as valve spring might bottom and result Pistons and cylinder bores should be measured at
in serious damage. normal room temperature, 21°C (70°F).
(5) I f reading is not within specified limits: PISTON PIN BORE DIAMETER
(a) Check sprocket index marks.
(b) Inspect timing chain for wear.
(c) Check accuracy of DC mark on timing indica
tor.
T H I N G CHAIN ST1ETCH
(1) Place a scale next to the timing chain so that
any movement of the chain can be measured.
(2) Place a torque wrench and socket over cam
shaft sprocket attaching bolt. Apply torque in the
direction of crankshaft rotation to take up slack; 41
N-m (30 ft. lbs.) torque with cylinder head installed
or 20 N-m (15 ft. lbs.) torque with cylinder head
removed. With torque applied to the camshaft
sprocket bolt, crankshaft should not be permitted to
move. I t may be necessary to block the crankshaft to
prevent rotation.
(3) Hold a scale with dimensional reading even
with the edge of a chain link. With cylinder heads A
installed, apply 14 N-m (30 ft. lbs.) torque in the PISTON A DIA = PISTON DIAMETER BORE DIAMETER
SIZE MIN. mm (IN.) MAX. mm (IN.) MIN. mm (IN.) MAX. mm (IN.)
reverse direction. With the cylinder heads removed, A 99.280 (3.9087) 99.294 (3.9092) 99.306 (3.9097) 99.319(3.9102)
apply 20 N-m (15 ft. lbs.) torque in the reverse direc B 99.294 (3.9092) 99.306 (3.9097) 99.319(3.9102) 99.332 (3.9107)
tion. Note the amount of chain movement (Fig. 6). C 99.306 (3.9097) 99.319(3.9102) 99.332 (3.9107) 99.344 (3.9112)
D 99.319(3.9102) 99.332 (3.9107) 99.344 (3.9112) 99.357(3.9117)
E 99.332 (3.9107) 99.344 (3.9112) 99.357(3.9117) 99.370(3.9122)
J9509-80
Fig. 7 Piston Measurements

FITTING RINGS
(1) Measurement of end gaps:
(a) Measure piston ring gap 2 in. from bottom of
cylinder bore. An inverted piston can be used to
push the rings down to ensure positioning rings
squarely in the cylinder bore before measuring.
(b) Insert feeler gauge in the gap. The top com
Fig. 6 Measuring Timing Chain Wear and Stretch pression ring gap should be between 0.254-0.508
(4) Install a new timing chain, i f its movement mm (0.010-0.020 in.). The second compression ring
exceeds 3.175 mm (1/8 inch). gap should be between 0.508-0.762 mm
(0.020-0.030 in.). The oil ring gap should be 0.254-
FITTING PISTONS 1.270 mm (0.010-0.050 in.).
Check the cylinder block bore for out-of-round, (c) Rings with insufficient end gap may be prop
taper, scoring, or scuffing. erly filed to the correct dimension. Rings with
Check the pistons for taper and elliptical shape excess gaps should not be used.
before they are fitted into the cylinder bore (Fig. 7). (2) Install rings, and confirm ring side clearance:
Piston and cylinder wall must be clean and dry. (a) Install oil rings being careful not to nick or
Specified clearance between the piston and the cylin scratch the piston. Install the oil control rings
der wall is 0.013-0.038 mm (0.0005-0.0015 in.) at according to instructions in the package. I t is not
21°C (70°F). necessary to use a tool to install the upper and
I - 28 3.SL i ^ i h i
SEitWlCE ? R O £ £ D U R £ S (Continued)
lower ralk. Insert cll rail spacer first, then side TO? COMPRESSION
CHAMFER
rails. \
RING
- c) Install the second compression rings using /
Installation Tool 0-4184. The compression rings
must be installed with the identification mark face
up (toward top of piston) and chamfer facing down.
An identification mark on the ring is a drill point, SECOND
a stamped letter "O", an oval depression, or the COMPRESSION
word "TOP" (Fig. 8) (Fig. 10). RING
(c) Using a ring installer, install the top com
pression ring with - the chamfer facing up (Fig. 9) :HAMFER
PISTON J9409-37
(Fig. 10). An identification mark on the ring is a
drill point, a stamped letter "O", an oval depression Fig, 10 Compression Ring Chamfer Location
or the word "TOP" facing up. (Typical)
(d) Measure side clearance between piston ring
and ring land. Clearance should be 0.074-0.097 mm (b) Arrange second compression ring 90° clock
(0.0029-0.0038 in,) for the compression rings. The wise from the oil ring rail gap (Fig. 11).
steel rail oil ring should be free in groove, but OIL RING
should not exceed 0.246 mm (0.0097 in.) side clear SPACER GAP
ance.
(e) Pistons with insufficient, or excessive, side
clearance should be replaced.
SECOND
SECOND COMPRESSION RING COMPRESSION
CHAMFER TOP
( B L A C K CAST IRON) COMPRESSION
RING GAP
OIL RING RAIL
RING GAP
GAP (TOP)
OIL RING RAIL

GAP (BOTTOM) J9309-80
TWO Fig, 11 Proper Ring Installation

DOTS J9009-46
CONNECTING ROD BEARINGS
Fig, 8 Second Compression Ring identification Fit all rods on a bank until completed. DO NOT
(Typical) alternate from one bank to another, because connect
ing rods and pistons are not interchangeable from
^^5Nv TOP COMPRESSION R I N G one bank to another.
X \ % \ (GRAY IN COLOR)
x
* - > \ 'Ox. The bearing caps are not interchangeable and
should be marked at removal to ensure correct
CHAMFER
' assembly.
Each bearing cap has a small V-groove across the
parting face. When installing the lower bearing shell,
be certain that the V-groove in the shell is in line
with the 'V-groove in the cap. This provides lubrica
tion of the cylinder wall in the opposite bank.
The bearing shells must be installed so that the
J9009-48
tangs are in the machined grooves in the rods and
caps.
Fig, 9 Top Compression Ring Identification (Typical) Limits of taper or out-of-round on any crankshaft
journals should be held to 0.025 mm (0.001 in.).
(3) Orient the rings:
Bearings are available in 0.025 mm (0.001 in.), 0.051
(a) .Arrange top compression ring 90° counter
mm (0.002 in.), 0.076 mm (0.003 in.), 0.254 mm
clockwise from the oil ring rail gap (Fig. 11).
(0.010 in.) and 0.305 mm (0.012 in.) undersize.
Install the bearings in pairs. DO NOT use a new
SEHWICE PROCEDURES (Gofttimted)
bearing half with, an old bearing half. DO NOT Ifcclersize Journal Identification S t a m p
file the rods or bearing caps.
ROD - 0.025r.m (0.001 in.) Rl-R2R3-.. ;c r
CRANKSHAFT MAIN BEARINGS MAIN - 0.025mm (0.001 in.) M 1 - M 2 - M 3 or M 4

Bearing caps are NOT interchangeable and should
be marked at removal to ensure correct assembly. STEEL STAMP IDENTIFICATION
Upper and lower bearing halves are NOT inter R (ROD) A N D / O R M (MAIN) FOLLOWED
BY THE ROD OR MAIN NUMBER
changeable. Lower main bearing halves of No. 1 and
3 are interchangeable.
Upper and lower No. 2 bearing halves are flanged n
to carry the crankshaft thrust loads. They are NOT
interchangeable with any other bearing halves in the n-l ^——Lf
i 1
engine (Fig. 12). Bearing shells are available in stan !! !

dard and the following undersizes: 0.25 mm (0.001
in.), 0.051 mm (0.002 in.), 0.076 mm (0.003 in.), 0.254 #6- #5 #4 #3 ifl i£U J92G9-134
mm (0.010 in.) and 0.305 mm (0.012 in.). Never
install an undersize bearing that will reduce clear Fig. 13 Location of Crankshaft Identification
ance below specifications.
R E M O V A L $MB INSTALLATION
UPPER
ENGINE FRONT MOUNTS
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Position fan to ensure clearance for radiator
top tank and hose.
CAUTION: DO NOT lift the engine by the intake

manifold.
(3) Install engine support/lifting fixture.

(5) Lift the engine SLIGHTLY and remove the
Fig. 12 Main Bearing Identification thru-bolt and nut (Fig. 14).
CRANKSHAFT (6) Remove engine support bracket/cushion bolts
A crankshaft that has undersize journals will be (Fig. 14). Remove the support bracket/cushion and
stamped with 1/4 inch letters near the notch of the heat shields.
No.6 crankshaft counterweight (Fig. 13).
FOR E X A M P L E : R2 stamped on the No. 6 crank ENGINE MOUNT
shaft counterweight indicates that the No. 2 rod jour HEAT SHIELD
nal is 0.025 mm (0.001 in.) undersize. M4 indicates
that the No. 4 main journal is 0.025 mm (0.001 in.) ENGINE SUPPORT
BRACKET/CUSHION
undersize. R 3 M2 indicates that the No. 3 rod journal
and the No. 2 main journal are 0.025 mm (0.001 in.)
undersize.
When a crankshaft is replaced, all main and con THRU-BOLT
necting rod bearings should be replaced with new
replaced.
RESTRICTION PADS
J9409-144
Fig. 14 Engine Front Mounts

9 - 31 3.9L E l l i N E — * BR
REMOVAL AND INSTALLATION |C©ntinueiJ
INSTALLATION (2) Position support cushion to transmission sup
(1) With engine raised SLIGHTLY, position the port bracket. Install stud nuts and tighten to 41 N-m
engine support bracket/cushion and heat shields to (30 ft. lbs.) torque.
the block. Install new bolts and tighten to 81 N-m (60 (3) Using the transmission jack, lower the trans
ft. lbs.) torque. mission and support cushion onto the crossmember
(2) Install the through-bolt into the engine support (Fig. 16).
bracket/cushion. (4) Install the support cushion bolts and tighten to
(3) Lower engine with support/lifting fixture while 41 N-m (30 ft. lbs.) torque.
guiding the engine bracket/cushion and through-bolt (5) Remove the transmission, jack.
into support cushion brackets (Fig. 15). (6) Lower the vehicle.
ENGINE ASSEMBLY
REMOVAL
(1) Remove the battery.
(2) Drain cooling system. Refer to Group 7, Cooling
System, for the proper procedure.
(3) Remove the upper crossmember and top core
support.
(4) Remove the transmission oil cooler.
(5) Discharge the air conditioning system, i f
equipped. Refer to Group 24, Heating and Air Condi
tioning for service procedures.
(6) Remove the serpentine belt. Refer to Group 7,
Cooling System.
(7) Remove the A/C compressor with the lines
attached. Set aside.
(8) I f equipped, remove the condenser.
(9) Remove the washer bottle.
CUSHION
(10) Disconnect the top radiator hose.
BRACKET (11) Remove the fan.
J9409-54 (12) Remove the fan shroud.
(13) Disconnect the lower radiator hose.
Fig. 15 Positioning Engine Front Mounts (14) Remove radiator. Refer to Group 7, Cooling
(4) Install through-bolt nuts and tighten the nuts System.
to 102 N-m (75 ft. lbs.) torque. (15) Remove the generator with the wire connec
(5) Lower the vehicle. tions. Refer to Group 8B, Battery/Starter/Generator
(6) Remove lifting fixture. Service.
(16) Remove the air cleaner box.
ENGINE REAR MOUNT (17) Disconnect the throttle linkage.
(18) Remove throttle body.
REMOVAL (19) Remove the intake manifold. Refer to Group
(1) Raise the vehicle on a hoist. 11, Exhaust System and Intake Manifold.
(2) Position a transmission jack in place. (20) Remove the distributor cap and wiring.
(3) Remove support cushion stud nuts (Fig. 16). (21) Disconnect the heater hoses.
(4) Raise rear of transmission and engine (22) Disconnect the power steering hoses, i f
SLIGHTLY. equipped.
(5) Remove the bolts holding the support cushion (23) Disconnect the transmission cooler lines.
to the transmission support bracket. Remove the sup (24) Perform the Fuel System Pressure release
port cushion. procedure. Refer to group 14, Fuel system. Discon
(6) I f necessary, remove the bolts holding the nect the fuel lines.
transmission support bracket to the transmission. (25) On Manual Transmission vehicles, remove the
shift lever. Refer to Group 2 1 , Transmissions.
INSTALLATION (26) Raise and support the vehicle on a hoist.
(1) I f removed, position the transmission support (27) Remove the drain plug and drain the engine
bracket to the transmission, install new attaching oil.
bolts and tighten to 88 N-m (65 ft. lbs.) torque. (28) Remove engine front mount through-bolt nuts.
BR — — — — — — — — 3 . 9 L ENGINE I - 31
REMOVAL AND INSTALLATION (Continued!
4X4
3500 MANUAL 4X2 4X4
4 5 0 0 ALL AUTOMATICS AUTOMATICS
J9509-126
Fig. 16 Engine Rear Support Cushion Assemblies

(29) Remove the transmission cooler line brackets (5) Install the prop shaft. Refer to Group 16, Pro
from oil pan. peller Shaft.
(30) Disconnect exhaust pipe at manifold. (6) Install the dust shield and transmission cover.
(31) Disconnect the starter wires. Remove starter (7) Install the starter and connect the starter
motor. Refer to Group 8B, Battery/Starter/Generator wires. Refer to Group 8B, Battery/Starter/Generator
Service. Service.
(32) Remove the dust shield and transmission (8) Install exhaust pipe to manifold.
cover. (9) Install the transmission cooler line brackets
(33) Refer to Group 21, Transmissions for trans from oil pan.
mission removal. (10) Install engine front mount through-bolt nuts.
(34) Lower the vehicle. Tighten the nuts.
(11) Install the drain plug and tighten to 34 N-m
CAUTION: DO NOT lift the engine by the intake (25 ft. lbs.) torque.
manifold. (12) Lower the vehicle.
(13) Remove engine-lifting fixture.
(35) Install an engine lifting fixture. (14) On Manual Transmission vehicles, install the
(36) Remove engine from vehicle and install shift lever. Refer to Group 21, Transmissions.
engine assembly on a repair stand. (15) Connect the fuel lines.
(16) Connect the transmission cooler lines.
INSTALLATION
(17) Connect the power steering hoses, i f equipped.
(1) Remove engine from the repair stand and posi
(18) Connect the heater hoses.
tion in the engine compartment. Position the
(19) Install the distributor cap and wiring.
through-bolt into the support cushion brackets.
(20) Install the intake manifold. Refer to Group 11,
(2) Install an engine support fixture.
Exhaust System and Intake Manifold.
(3) Raise and support the vehicle on a hoist.
(21) Using a new gasket, install throttle body.
(4) Refer to Group 21, Transmissions for transmis
Tighten the throttle body bolts to 23 N-m (200 in.
sion installation.
lbs.) torque.
9 - 32 3.9L ENGINE BR
(22) Connect the throttle linkage. (3) Install closed crankcase ventilation system and
(23) Install the air cleaner box. evaporation control system.
(24) Install the generator and wire connections. (4) Connect the negative cable to the battery.
Refer to Group 8B, Battery/Starter/Generator Ser
vice. CYLINDER HEAD COMPONENTS—IN WEHICLE
(25) Install radiator. Refer to Group 7, Cooling
System. SERWICE
(26) Connect the lower radiator hose.
ROCKER ARMS AND PUSH RODS
(27) Install the fan shroud.
(28) Install the fan. RE10WAL
(29) Connect the top radiator hose.
(1) Disconnect spark plug wires by pulling on the
(30) Install the washer bottle.
boot straight out in line with plug.
(31) I f equipped, install the condenser.
(2) Remove cylinder head cover and gasket.
(32) Install the A/C compressor with the lines
(3) Remove the rocker arm bolts and pivots (Fig.
attached.
18). Place them on a bench in the same order as
(33) Install the serpentine belt. Refer to Group 7,
removed.
Cooling System.
(4) Remove the push rods and place them on a
(34) Evacuate and charge the air conditioning sys
bench in the same order as removed.
tem, i f equipped. Refer to Group 24, Heating and Air
ROCKER
Conditioning for service procedures. ARMS
(35) Install the transmission oil cooler.
(36) Install the upper crossmember and top core
support.
(37) Add coolant to the cooling system. Refer to
Group 7, Cooling System for the proper procedure.
(38) Install the battery.
(39) Road test vehicle.
CYLINDER HEAD COWER

A steel-backed silicone gasket is used with the cyl
inder head cover (Fig. 17). This gasket can be used
again.
CYLINDER HEAD
COVER GASKET V
J9209-66
Fig. 18 Rocker Arms

ilSTALLATlOi
J9209-104
(1) Rotate the crankshaft until the V6 mark lines
Fig. 17 Cylinder Head Cover Gasket
up with the TDC mark on the timing chain case
cover. This mark is located 147° ATDC from the N o . l
REMOVAL firing position.
(2) Disconnect closed ventilation system and evap CAUTION: DO NOT rotate or crank the engine dur
oration control system from cylinder head cover. ing or immediately after rocker arm installation.
(3) Remove cylinder head cover and gasket. The Allow the hydraulic roller tappets adequate time to
gasket may be used again. bleed down (about 5 minutes).
INSTALLATION (2) Install the push rods in the same order as

(1) Install the cylinder head cover gasket onto the removed.
head rail.
(2) Position the cylinder head cover onto the gas
ket. Tighten the bolts to 11 N-m (95 in. lbs.) torque.

(3) Install rocker arm and pivot assemblies in the SPARK SPARK INTAKE
same order as removed. Tighten the rocker arm bolts PLUGS PLUG VALVE
(4) Install cylinder head cover.
(5) Connect spark plug wires.
VALVE STEM SHIELDS AND SPRINGS
REMOVAL
(1) Set engine basic timing to Top Dead Center
(TDC).
(2) Remove the air cleaner.
(3) Remove cylinder head covers and spark plugs.
(4) Remove coil wire from distributor and secure to
EXHAUST INTAKE EXHAUST
good ground to prevent engine from starting. VALVE VALVES VALVES J9309-35
(5) Using suitable socket and flex handle at crank
shaft retaining bolt, turn engine so the No.l piston is
Fig. 19 Cylinder Head Assembly
at TDC on the compression stroke.
(6) Remove rocker arms. (6) Remove the air cleaner.
(7) With air hose attached to an adapter installed (7) Perform fuel system pressure release proce
in N o . l spark plug hole, apply 620-689 kPa (90-100 dure. Before attempting any repairs refer to Group
psi) air pressure. 14, Fuel Systems.
(8) Using Valve Spring Compressor Tool (8) Disconnect the fuel lines.
MD-998772A, compress valve spring and remove (9) Disconnect accelerator linkage and i f so
retainer valve locks and valve spring. equipped, the speed control and transmission kick-
down cables.
INSTALLATION (10) Remove the return spring.
(1) Install seals on the exhaust valve stem and (11) Remove distributor cap and wires.
position down against valve guides. (12) Disconnect the coil wires.
(2) The intake valve stem seals should be pushed (13) Disconnect heat indicator sending unit wire.
firmly and squarely over the valve guide using the (14) Disconnect heater hoses and bypass hose.
valve stem as a guide. DO NOT force seal against top (15) Remove cylinder head covers and gaskets.
of guide. When installing the valve retainer locks, (16) Remove intake manifold and throttle body as
compress the spring only enough to install the locks. an assembly. Discard the flange side gaskets and the
(3) Follow the same procedure on the remaining 5 front and rear cross-over gaskets.
cylinders using the firing sequence 1-6-5-4-3-2. Make (17) Remove exhaust manifolds.
sure piston in cylinder is at TDC on the valve spring (18) Remove rocker arm assemblies and push rods.
that is being removed. Identify to ensure installation in original locations.
(4) Remove adapter from the N o . l spark plug hole. (19) Remove the head bolts from each cylinder
(5) Install rocker arms. head and remove cylinder heads. Discard the cylin
(6) Install covers and coil wire to distributor. der head gasket.
(7) Install air cleaner. (20) Remove spark plugs.
'[INSTALLATION
CYLINDER HEADS (1) Position the new cylinder head gaskets onto
The alloy cast iron cylinder heads (Fig. 19) are the cylinder block.
held i n place by eight bolts. The spark plugs are (2) Position the cylinder heads onto head gaskets
located at the peak of the wedge between the valves. and cylinder block.
(3) Starting at top center, tighten all cylinder head
REMOVAL • • bolts, in sequence, to 68 N-m (50 ft. lbs.) torque (Fig.
(1) Disconnect the negative cable from the battery. 20). Repeat procedure, tighten all cylinder head bolts
(2) Drain cooling system. Refer to Group 7, Cooling to 143 N-m (105 ft. lbs.) torque. Repeat procedure to
System for the proper procedures. confirm that all bolts are at 143 N-m (105 ft. lbs.)
(3) Remove the intake manifold-to-generator torque.
bracket support rod. Remove the generator.
(4) Remove closed crankcase ventilation system.
(5) Disconnect the evaporation control system.
9 - 34 3 J L ENGINE BR
(22) Fill cooling system. Refer to Group 7, Cooling
System for proper procedure.
VALVES AND VALVE SPRINGS—CYLINDER HEAD

RE10VED
REMOVAL
(1) Compress valve springs using Valve Spring
Compressor Tool MD-998772-A.
(2) Remove valve retaining locks, valve spring
retainers, valve stem seals, and valve springs.
(3) Before removing valves, remove any burrs from
valve stem lock grooves to prevent damage to the
valve guides. Identify valves to ensure installation in
original locations.
Fig. 20 Cylinder Head Bolt -Tightening Sequence
INSTALLATION
CAUTION: When tightening the rocker arm bolts, (1) Coat valve stems with lubrication oil and insert
be sure the piston in that cylinder is NOT at TDC. them in cylinder head.
Contact between the waives and piston could occur. (2) I f valves or seats are reground, check valve
(4) Install push rods and rocker arm assemblies in stem height. I f valve is too long, replace cylinder
their original positions. Tighten the bolts to 28 N-m head.
(21 ft. lbs.) torque. (3) Install new seals on all valve guides. Install
(5) Install the intake manifold and throttle body valve springs and valve retainers.
assembly. Refer to Group 11, Exhaust System and (4) Compress valve springs with Valve Spring
Intake Manifold. Compressor Tool MD-998772A, install locks and
(6) Install exhaust manifolds. Tighten , the bolts release tool. I f valves and/or seats are ground, mea
and nuts to 34 N-m (25 ft. lbs.) torque. sure the installed height of springs. Be sure the mea
(7) Adjust spark plugs to specifications. Refer to surement is taken from bottom of spring seat in
Group 8D, Ignition System. Install the plugs and cylinder head to the bottom surface of spring
tighten to 41 N-m (30 ft. lbs.) torque. retainer. I f spacers are installed, measure from the
(8) Install coil wires. top of spacer. I f height is greater than 42.86 mm
(9) Connect heat Indicator sending unit wire. (1-11/16 inches), install a 1.587 mm (1/16 in.) spacer
(10) Connect the heater hoses and bypass hose. in head counterbore. This should bring spring height
(11) Install distributor cap and wires. back to normal 41.27 to 42.86 mm (1-5/8 to 1-11/16
(12) Hook up the return spring. in.).
(13) Connect the accelerator linkage and, i f so
equipped, the speed control and transmission kick- HYDRAULIC TAPPETS
down cables.
(14) Install the fuel lines. REMOVAL
(15) Install the generator and drive belt. Tighten (1) Remove the air cleaner.
generator mounting bolt to 41 N-m (30 ft. lbs.) (2) Remove cylinder head cover.
torque. Tighten the adjusting strap bolt to 23 N-m (3) Remove rocker assembly and push rods. Iden
(200 in. lbs.) torque. Refer to Group 7, Cooling Sys tify push rods to ensure installation in original loca
tem for adjusting the belt tension. tions.
(16) Install the intake manifold-to-generator (4) Remove intake manifold.
bracket support rod. Tighten the bolts. (5) Remove yoke retainer and aligning yokes.
(17) Place the cylinder head cover gaskets in posi (6) Slide Hydraulic Tappet Remover/Installer Tool
tion and install cylinder head covers. Tighten the C-4129-A through opening in cylinder head and seat
bolts to 11 N-m (95 in. lbs.) torque. tool firmly in the head of tappet.
(18) Install closed crankcase ventilation system. (7) Pull tappet out of bore with a twisting motion.
(19) Connect the evaporation control system. If all tappets are to be removed, identify tappets to
(20) Install the air cleaner. ensure installation in original location.
(21) Install the heat shields. Tighten the bolts to (8) I f the tappet or bore in cylinder block is scored,
41 N-m (30 ft. lbs.) torque. scuffed, or shows signs of sticking, ream the bore to
next oversize. Replace with oversize tappet.

INSTALLATION
(1) Lubricate tappets.
(2) Install tappets and push rods in their original
positions. Ensure that the oil feed hole in the side of
the tappet body faces up (away from the crankshaft).
(3) Install aligning yokes with ARROW toward
camshaft.
(4) Install yoke retainer. Tighten the bolts to 23
N-m (200 in. lbs.) torque. Install intake manifold.
(5) Install push rods in original positions.
(6) Install rocker arms.
(7) Install cylinder head cover.
Fig. 22 Distributor Driveshaft Bushing Installation
(8) Start and operate engine. Warm up to normal
operating temperature. CAUTION: This procedure MUST be followed when
installing a new bushing or seizure to shaft may occur.
CAUTION; To prevent damage to valve mechanism,
engine must not 'be run above fast idle until all
hydraulic tappets have filled with oil and have
become quiet.
DISTRIBUTOR DRIVE SHAFT BUSHING
REMOVAL
(1) Remove distributor. Refer to Group 8D, Igni
tion Systems for the proper procedure.
(2) Remove the intake manifold. Refer to Group
11, Exhaust System and Intake Manifold. Fig. 23 Burnishing Distributor Driveshaft Bushing
(3) Insert Distributor Drive Shaft Bushing Puller
Tool C-3052 into old bushing and thread down until a (4) Install the intake manifold. Refer to Group 11,
tight fit is obtained (Fig. 21). Exhaust System and Intake Manifold.
(4) Hold puller screw and tighten puller nut until
DISTRIBUTOR INSTALLATION
bushing is removed.
NOTE: Before installing the distributor, the oil pump
drive shaft must be aligned to number one cylinder.
(1) Rotate crankshaft until No. 1 cylinder is at top

dead center on the firing stroke.
(2) When in this position, the timing mark of
vibration damper should be under "0" on the timing
indicator.
(3) Install the shaft so that after the gear spirals
into place, i t will index with the oil pump shaft. The
slot on top of oil pump shaft should be aligned
toward the left front intake manifold attaching bolt
Fig. 21 Distributor Driveshaft Bushing Removal hole (Fig. 24).
INSTALLATION (4) Install distributor. Refer to Group 8D, Ignition
(1) Slide new bushing over burnishing end of Dis Systems for the proper procedure.
tributor Drive Shaft Bushing Driver/Burnisher Tool After the distributor has been installed, its rota
C-3053. Insert the tool and bushing into the bore. tional position must be set using the S E T SYNC
(2) Drive bushing and tool into position, using a mode of the DRB scan tool. Refer to Checking Dis
hammer (Fig. 22). tributor Position following the Distributor Installa
(3) As the burnisher is pulled through the bushing, tion section in Group 8D, Ignition System.
the bushing is expanded tight in the block and bur Do not attempt to adjust ignition timing by
nished to correct size (Fig. 23). DO NOT ream this rotating the distributor. It has no effect on igni
bushing. tion timing. Adjusting distributor position will
affect fuel synchronization only.
R E M O V A L AMD I N S T A L L A T I O N {Continued)
Fig. 26 Installing Vibration Damper

(4) Install the crankshaft pulley. Tighten the pul
ley bolts to 23 N-m (200 in. lbs.) torque.
(5) Install the serpentine belt. Refer to Group 7,
Fig. 24 Position of Oil Pump Shaft Slot Cooling System.
(6) Install the cooling system fan. Tighten the
VIBRATION DAMPER
bolts to 23 N-m (17 ft. lbs.) torque.
REMOVAL (7) Position the fan shroud and install the bolts.
(1) Disconnect the negative cable from the battery. Tighten the retainer bolts to 11 N-m (95 in. lbs.) torque.
(2) Remove fan shroud retainer bolts and set (8) Connect the negative cable to the battery
shroud back over engine.
(3) Remove the cooling system fan. TIMING CHAIN COVER
REMOVAL
Cooling System.
(5) Remove the vibration damper pulley.
(2) Drain cooling system. Refer to Group 7, Cooling
(6) Remove vibration damper bolt and washer from
System.
end of crankshaft.
(7) Install bar and screw from Puller Tool Set
Cooling System.
C-3688. Install two bolts with washers through the
(4) Remove water pump. Refer to Group 7, Cooling
puller tool and into the vibration damper (Fig. 25).
System.
(5) Remove power steering pump. Refer to Group
19, Steering.
(6) Remove vibration damper.
(7) Loosen oil pan bolts and remove the front bolt
at each side.
(8) Remove the cover bolts.
(9) Remove chain case cover and gasket using
extreme caution to avoid damaging oil pan gasket.
(10) Place a suitable tool behind the lips of the oil
seal to pry the oil seal outward. Be careful not to
J9209-81 damage the crankshaft seal surface of cover (Fig. 27).
rig. 25 Vibration Damper Assembly
(8) Pull vibration damper off of the crankshaft.
INSTALLATION
(1) Position the vibration damper onto the crank
shaft.
(2) Place installing tool, part of Puller Tool Set
C-3688, in position and press the vibration damper
onto the crankshaft (Fig. 26).
(3) Install the crankshaft bolt and washer. Tighten
the bolt to 183 N-m (135 ft. lbs.) torque.
Fig. 27 Removal of Front Crankshaft Oil Seal
INSTALLATION SPECIAL TOOL
(1) Be sure mating surfaces of chain case cover 6635
and cylinder block are clean and free from burrs.
(2) Using a new cover gasket, carefully install
chain case cover to avoid damaging oil pan gasket.
Use a small amount of Mopar Silicone Rubber Adhe
sive Sealant, or equivalent, at the joint between tim
ing chain cover gasket and the oil pan gasket. Finger
tighten the timing chain cover bolts at this time.
CAUTION: If chain cower is replaced for any rea

son, be sure the oil hole (passenger side of cover)
Is p l u g g e d .
(3) Place the smaller diameter of the oil seal over

Front Oil Seal Installation Tool 6635 (Fig. 28). Seat
the oil seal in the groove of the tool.
CRANKSHAFT k INSTALL THIS
FRONT OIL END INTO
SEAL SPECIAL TOOL TIMING'
6635 CHAIN
COVER J9309-45-
Fig. 29 Position Tool and Seal onto Crankshaft
^ J9309-44
Fig. 28 Placing Oil Seal on Installation Tool 6635

(4) Position the seal and tool onto the crankshaft
(Fig. 29).
(5) Tighten the four lower chain case cover bolts to
13N-m (10 ft.lbs.) to prevent the cover from tipping
during seal installation.
(6) Using the vibration damper bolt, tighten the
bolt to draw the seal into position on the crankshaft
(Fig. 30).
(7) Loosen the four bolts tightened i n Step 4 to
allow realignment of front cover assembly. J9309-46
(8) Tighten chain case cover bolts to 41 N-m (30 ft. Fig. 30 Installing Oil Seal
lbs.) torque. Tighten oil pan bolts to 24 N-m (215 in. (13) Install power steering pump. Refer to Group
lbs.) torque. 19, Steering.
(9) Remove the vibration damper bolt and seal (14) Install the serpentine belt. Refer to Group 7,
installation tool. Cooling System.
(10) Inspect the seal flange on the vibration (15) Install the cooling system fan. Tighten the
damper. bolts to 23 N-m (17 ft. lbs.) torque.
(11) Install vibration damper. (16) Position the fan shroud and install the bolts.
(12) Install water pump and housing assembly Tighten the bolts to 11 N-m (95 in. lbs.) torque.
using new gaskets. Refer to Group 7, Cooling System. (17) Fill cooling system. Refer to Group 7, Cooling
Tighten bolts to 41 N-m (30 ft. lbs.) torque. System for the proper procedure.
TIMING CHAIN CHAIN
SPROCKET
REMOVAL
(1) Remove timing chain cover.
(2) Remove camshaft sprocket attaching bolt and
remove timing chain with crankshaft and camshaft
sprockets.
INSTALLATION
(1) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on an exact
imaginary center line through both camshaft and
crankshaft bores. Fig. 32 Camshaft and Sprocket Assembly
(2) Place timing chain around both sprockets. (6) Remove distributor and lift out the oil pump
(3) Turn crankshaft and camshaft to line up with and distributor drive shaft.
keyway location in crankshaft sprocket and in cam (7) Remove camshaft thrust plate and note loca
shaft sprocket. tion of oil tab (Fig. 33).
(4) Lift sprockets and chain (keep sprockets tight
against the chain In position as described).
(5) Slide both sprockets evenly over their respec
tive shafts and use a straightedge to check alignment
of timing marks (Fig. 31).
Fig. 81 Alignment of Timing Marks

(6) Install the camshaft bolt. Tighten the bolt to 68
(7) Check camshaft end play. The end play should
be 0.051-0.152 mm (0.002-0.006 in.) with a new
thrust plate and up to 0.254 mm (0.010 in.) with a Fig. 38 Timing Chain Oii Tab Installation
used thrust plate. I f not within these limits install a (8) Install a long bolt into front of camshaft to
new thrust plate. facilitate removal of the camshaft. Remove camshaft,
being careful not to damage cam bearings with the
CAMSHAFT cam lobes.
This procedure requires that the engine is removed
from the vehicle. INSTALLATION
The camshaft has- an integral oil pump and distrib . (1) Lubricate camshaft lobes and camshaft bearing
utor drive gear (Fig. 32). journals and insert the camshaft to within 51 mm (2
inches) of its final position In cylinder block.
REmOWAL
(1) Remove Intake manifold. NOTE; Whenever an engine has been rebuilt, a new
(2) Remove cylinder head covers. camshaft and/or new tappets installed, add one pint
(3) Remove timing case cover and timing chain. of Mopar Crankcase Conditioner, or equivalent. The
(4) Remove rocker arms. oil mixture should be left in engine for a minimum
(5) Remove push rods and tappets. Identify each of 805 km (500 miles). Drain at the next normal oil
part so it can be installed in the original locations. change.
BR 3 J L ENGINE 9 - 39
R E M O V A L Mm INSTALLATION (Continued)
( 2 ) Install Camshaft Gear Installer Tool C-3509 (11) Measure camshaft end play. Refer to Specifica
with tongue back of distributor drive gear (Fig. 3 4 ) . tions for proper clearance. I f not within limits, install
a new thrust plate.
(12) Each tappet reused must be installed in the
same position at which it was removed. When cam
shaft is replaced, a l l of the tappets must be
replaced.
CAMSHAFT SEARINGS
REMOVAL
(1) With engine completely disassembled, drive out
rear cam bearing core hole plug.
(2) Install proper size adapters and horseshoe
Fig. 34 Camshaft Holding Tool C-3509 (Installed washers (part of Camshaft Bearing Remover/Installer
Position) Tool C-3132-A) at back of each bearing shell. Drive
out bearing shells (Fig. 36).
(3) Hold tool i n position with a distributor lock-
plate bolt. This tool will restrict camshaft from being
pushed in too far and prevent knocking out the welch
plug in rear of cylinder block. Tool should remain
installed u n t i l the camshaft and crankshaft
sprockets and timing chain have been installed.
( 4 ) Install camshaft thrust plate and chain oil tab.
Be sure tang enters lower right hole i n t h r u s t
plate. Tighten bolts to 2 4 N-m ( 2 1 0 in. lbs.) torque.
Top edge of tab should be flat against thrust plate in
order to catch oil for chain lubrication.
sprocket on the bench with timing marks on an exact Fig. 36 Camshaft Bearings Removal and Installation
imaginary center line through both camshaft and with Tool C-3132-A
crankshaft bores.
INSTALLATION
(6) Place timing chain around both sprockets.
(7) Turn crankshaft and camshaft to line up with (1) Install new camshaft bearings with Camshaft
Bearing Remover/Installer Tool C-3132-A by sliding
keyway location in crankshaft sprocket and in cam
the new camshaft bearing shell over proper adapter.
shaft sprocket.
( 2 ) Position rear bearing in the tool. Install horse
shoe lock and, by reversing removal procedure, care
against the chain in position as described).
fully drive bearing shell into place.
(3) Install remaining bearings in the same man
ner. Bearings must be carefully aligned to bring oil
holes into full register with oil passages from the
main bearing. I f the camshaft bearing shell oil holes
are not in exact alignment, remove and install them
correctly. Install a new core hole plug at the rear of
camshaft. Be sure this plug does not leak.
REMOVAL
(1) Remove the oil pan.
( 2 ) Remove the oil pump from the rear main bear
ing cap.
(3) Identify bearing caps before removal. Remove
bearing caps one at a time.
(10) Install the camshaft bolt/cup washer. Tighten
bolt to 68 N-m (50 ft. lbs.) torque.
S - 40 3.91 ENGINE
R E M O V A L A N D INSTALLATION ( C o n t i n u e d )
(4) Remove upper half of bearing by inserting (8) Remove the one-piece gasket.
Crankshaft Main Bearing Remover/Installer Tool
C-3059 into the oil hole of crankshaft (Fig. 37). INSTALLATION
(5) Slowly rotate crankshaft clockwise, forcing out (1) Clean the block and pan gasket surfaces.
upper half of bearing shell. (2) Fabricate four alignment dowels from 5/16 X 1
1/2 inch bolts. Cut the head off the bolts and cut a
slot into the top of the dowel. This will allow easier
installation and removal with a screwdriver (Fig. 38).
1
k ^5/}6" x l / " BOLT
2
y
1
y, DOWEL
X
A
SLOT J9509-163
Fig. 38 Fabrication of Alignment Dowels

(3) Install the dowels in the cylinder block (Fig.
Fig. 37 Upper Main Bearing Removal and 39).
installation with Tool C-3059
INSTALLATION
Only one main bearing should be selectively fitted
while all other main bearing caps are properly tight
ened. A l l bearing capbolts removed during service
procedures are to be cleaned and oiled before instal
lation. DO NOT use a new bearing half with an old
bearing half.
When installing a new upper bearing shell, slightly
chamfer the sharp edges from the,plain side.
(1) Start bearing in place, and insert Crankshaft
Main Bearing Remover/Installer Tool C-3059 into oil
hole of crankshaft (Fig. 37).
(2) Slowly rotate crankshaft counterclockwise slid
ing the bearing into position. Remove Tool C-3059.
• (3) install the bearing caps. Clean and oil the
bolts. Tighten the capbolts to 115 N-m (85 ft. lbs.)
torque.
(4) install the oil pump.
(5) Install the oil pan. Fig. 39 Position of Dowels in Cylinder Block
OIL PAN (4) Apply small amount of Mopar® Silicone Rubber

Adhesive Sealant, or equivalent, in the corner of the
REMOVAL cap and the cylinder block.
(1) Disconnect the negative cable from the battery. (5) Slide the one-piece gasket over the dowels and
(2) Remove engine oil dipstick. onto the block.
(3) Raise vehicle. (6) Position the oil pan over the dowels and onto
(4) Drain engine oil. the gasket.
(5) Remove exhaust pipe. (7) Install the oil pan bolts. Tighten the bolts to 24
( 6 ) Remove left engine to transmission strut. N-m (215 in..lbs.) torque.
(7) Loosen the right side engine support bracket (8) Remove the dowels. Install the remaining oil
cushion through-bolt nut and raise the engine pan bolts. Tighten these bolts to 24 N-m (215 in. lbs.)
slightly. Remove oil pan by sliding backward and out. torque.
LIEMOV&IL Mm 1^STALL^TI@M ( C o n t i n u e d )
(9) Lower the engine into the support cushion OIL RING
S P A C E R GAP
brackets and tighten the through-bolt nut to the
proper torque.
(10) Install the drain plug. Tighten drain plug to
(11) Install the engine to transmission strut. SECOND
COMPRESSION
(12) Install exhaust pipe. TOP RING GAP
(13) Lower vehicle. COMPRESSION OIL RING RAIL
RING GAP
(14) Install dipstick. GAP (TOP)
(16) Fill crankcase with oil to proper level.
OIL PUMP
REMOVE OIL RING RAIL
(1) Remove the oil pan. GAP (BOTTOM) J9309-80

(2) Remove the oil pump from rear main bearing Fig. 40 Proper Ring installation
cap.
(3) immerse the piston head and rings in clean
INSTALLATION engine oil. Slide Piston Ring Compressor Tool C-385
(1) Install oil pump. During installation, slowly over the piston and tighten with the special wrench
rotate pump body to ensure driveshaft-to-pump rotor (part of Tool C-385). Be sure position of rings
shaft engagement. does not change d u r i n g this operation.
(2) Hold the oil pump base flush against mating (4) Install connecting rod bolt protectors on rod
surface on No. 4 main bearing cap. Finger-tighten bolts. The long protector should be installed on the
pump attaching bolts. Tighten attaching bolts to 41 numbered side of the connecting rod.
N-m (30 ft. lbs.) torque. (5) Rotate crankshaft so that the connecting rod
(3) Install the oil pan. journal is on the center of the cylinder bore. Be sure
connecting rod and cylinder bore number are the
PISTON AND CONNECTING ROD ASSEMBLY same. Insert rod and piston into cylinder bore and
guide rod over the crankshaft journal.
REMOVAL (6) Tap the piston down in cylinder bore, using a
(1) Remove the engine from the vehicle. hammer handle. At the same time, guide connecting
(2) Remove the cylinder head. rod into position on crankshaft journal.
(3) Remove the oil pan. (7) The notch, or groove, on top of piston must be
(4) Remove top ridge of cylinder bores with a reli pointing toward front of engine. The larger chamfer
able ridge reamer before removing pistons from cyl of the connecting rod bore must be installed toward
inder block. Be sure to keep tops of pistons covered crankshaft journal fillet.
during this operation. (8) Install rod caps. Be sure connecting rod, con
(5) Be sure each connecting rod and connecting rod necting rod cap, and cylinder bore number are the
cap is identified with the cylinder number. Remove same. Install nuts on cleaned and oiled rod bolts and
connecting rod cap. Install connecting rod bolt guide tighten nuts to 61 N-m (45 ft. lbs.) torque.
set on connecting rod bolts. (9) Install the oil pan.
(6) Pistons and connecting rods must be removed (10) Install the cylinder.head.
from top of cylinder block. When removing the (11) install the engine into the vehicle.
assemblies from the engine, rotate crankshaft so that
the connecting rod is centered in cylinder bore and at CRANKSHAFT
BDC. Be careful not to n i c k crankshaft journals.
(7) After removal, install bearing cap on the mat REMOVAL
ing rod. (1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear
ing cap.
(1) Be sure that compression ring gaps are stag (3) Identify bearing caps before removal. Remove
gered so that neither is i n line with oil ring rail gap. bearing caps and bearings one at a time.
(2) Before installing the ring compressor, be sure (4) Lift the crankshaft out of the block.
the oil ring expander ends are butted and the rail (5) Remove and discard the crankshaft rear oil
gaps located properly (Fig. 40). seals.
mmmmekh AND INSTALLATION (Continued)
(6) Remove and discard the front crankshaft oil MOPAR SILICONE SEALANT
seal. RUBBER ADHESIVE APPLIED
SEALANT
NOZZLE TIP
INSTALLATION
(1) Lightly oil the new upper seal Hps with engine
oil.
(2) Install the new upper rear bearing oil seal with
the white paint facing towards the rear of the engine.
(3) Position the crankshaft into the cylinder block.
(4) Lightly oil the new lower seal lips with engine
oil.
(5) Install the new lower rear bearing oil seal into
the bearing cap with the white paint facing towards
the rear of the engine. REAR M A I N
BEARING CAP J9309-87
(6) Apply 5 mm (0.20 in.) drop of Loctite 518, or
equivalent, on each side of the rear main bearing cap
(Fig. 41). DO NOT over-apply sealant or allow the Fig. 42 Apply Sealant to Bearing Cap-to~Block Joint
sealant to contact the rubber seal. Assemble bearing FRONT CRANKSHAFT OIL SEAL
cap to cylinder block immediately after sealant appli
cation.
The oil seal can.be replaced without removing the
, MOPAR SILICONE RUBBER ADHESIVE SEALANT SLOTSv
^ L O C T I T E 515 (OR EQUIVALENT). timing chain cover, provided that the cover is not
misaligned.
(3) I f front seal is suspected of leaking, check front
oil seal alignment to crankshaft. The seal installa
tion/alignment Tool 6635, should fit with minimum
CAP
ALIGNMENT interference. I f tool does not fit, the cover must be
SLOT removed and installed properly.
seal to pry the oil seal outward. Be careful not to
damage the crankshaft seal bore of cover.
REAR M A I N CRANKSHAFT, • INSTALL THIS
EARING CAP J9309-72 FRONT OIL END INTO
SEAL SPECIAL TOOL
6635
Fig. 41 Sealant Application to Bearing Cap
(7) To align the bearing cap, use cap slot, align
ment dowel, and cap bolts. DO NOT remove excess
material after assembly. DO NOT strike rear cap
more than two times for proper engagement.
(8) Clean and oil all cap bolts. Install all main
bearing caps. Install all cap bolts and alternately
tighten to 115 N-m (85 ft. lbs.) torque.
(9) Install oil pump.
(10) Apply Mopar Silicone Rubber Adhesive Seal
ant, or equivalent, at bearing cap-to-block joint to
J9309-44
provide cap-to-block and oil pan sealing (Fig. 42).
Apply enough - sealant so that a small amount is
Fig, 43 Placing Oii Seal on Installation Tool 6635
squeezed out. Withdraw nozzle and wipe excess seal
ant off the oil pan seal groove. INSTALLATION
(11) install new front crankshaft oil seal. (1) Place the smaller diameter of the oil seal over
(12) Immediately install the oil pan. Front Oil Seal Installation Tool 6635 (Fig. 43). Seat
the oil seal i n the groove of the tool.
(Fig. 44).
CRANKSHAFT REAR OIL SEALS
The service seal Is a two piece, Viton seal. The
upper seal half can be installed with crankshaft
removed from engine or with crankshaft installed.
When a new upper seal is installed, install a new
lower seal. The lower seal half can be installed only
with the rear main bearing cap removed.
UPPER SEAL —CRANKSHAFT REMOVED
1 E 1 0 W A L
(1) Remove the crankshaft. Discard the old upper

seal.
ilSTALLATlOl
(1) Clean the cylinder block rear cap mating sur
face. Be sure the seal groove is free of debris. Check
for burrs at the oil hole on the cylinder block mating
surface to rear cap.
(2) Lightly oil the new upper seal lips with engine
oil.
Fig. 44 Position Toot and Seal onto Crankshaft the white paint facing toward the rear of the engine.
(3) Using the vibration damper bolt, tighten the (4) Position the crankshaft into the cylinder block.
bolt to draw the seal Into position on the crankshaft (5) Lightly oil the new lower seal lips with engine
(Fig. 45). oil.
(4) Remove the vibration damper bolt and seal (6) Install the new lower rear bearing oil seal into
installation tool. the bearing cap with the white paint facing towards
(5) Inspect the seal flange on the vibration the rear of the engine.
damper. (7) Apply 5 mm (0.20 in.) drop of Loctite 518, or
(6) Install the vibration damper. equivalent, on each side of the rear main bearing cap
(7) Connect the negative cable to the battery. (Fig. 46). DO NOT over-apply sealant or allow the
sealant to contact the rubber seal. Assemble bearing
cation.

J9309-46 (8) To align the bearing cap, use cap slot, align
ment dowel, and cap bolts. DO NOT remove excess
Fig, 45 installing Oii Seal material after assembly. DO NOT strike rear cap
(9) Clean and oil all cap bolts. Install all main (4) Install the new lower rear bearing oil seal into
bearing caps. Install all cap bolts and alternately the bearing cap with the white paint facing toward
tighten to 115 N-m (85 ft. lbs.) torque. the rear of the engine.
(10) Install oil pump. (5) Apply 5 mm (0.20 in.) drop of Loctite 518, or
(11) Apply Mopar Silicone Rubber Adhesive Seal equivalent, on each side of the rear main bearing cap
ant, or equivalent, at bearing cap-to-block joint to (Fig. 46). DO NOT over-apply sealant or allow the
provide cap to block and oil pan sealing (Fig. 47). sealant to contact the rubber seal. Assemble bearing
Apply enough sealant so that a small amount is cap to cylinder block immediately after sealant appli
squeezed out. Withdraw nozzle and wipe excess seal cation. Be sure the white paint faces toward the rear
ant off the oil pan seal groove. of the engine.
(12) Install new front crankshaft oil seal. (6) To align the bearing cap, use cap slot, align
(13) Immediately install the oil pan. ment dowel, and cap bolts. DO NOT remove excess
MOPAR SILICONE SEALANT
RUBBER ADHESIVE APPLIED
(7) Install the rear main bearing cap with cleaned
and oiled cap bolts. Alternately tighten ALL cap bolts
(9) Apply Mopar Silicone Rubber Adhesive Sealant,
or equivalent, at bearing cap-to-block joint to provide
cap-to-block and oil pan sealing (Fig. 47). Apply
enough sealant until a small amount is squeezed out.
Withdraw nozzle and wipe excess sealant off the oil
pan seal groove.
(10) Immediately install the oil pan.
LOWER SEAL
Fig. 47 Apply Sealant to Bearing Cap-to-Block Joint RE1W0WAL

UPPER SEAL—CRANKSHAFT INSTALLED
REMOVAL ing cap.
(1) Remove the oil pan. (3) Remove the rear main bearing cap and discard
(2) Remove the oil pump from the rear main bear the old lower seal.
ing cap.
INSTALLATION
(3) Remove the rear main bearing cap. Remove
(1) Clean the rear main cap mating surfaces
and discard the old lower oil seal.
including the oil pan gasket groove.
(4) Carefully remove and discard the old upper oil
(2) Carefully install a new upper seal. Refer to
seal.
Upper Seal Replacement — Crankshaft Installed pro
11STALLAT101 cedure above.
(1) Clean the cylinder block mating surfaces before (3) Lightly oil the new lower seal lips with engine
oil seal installation. Check for burrs at the oil hole on oil.
the cylinder block mating surface to rear cap. (4) Install a new lower seal i n bearing cap with
(2) Lightly oil the new upper seal lips with engine the white paint facing the rear of engine.
oil. To allow ease of installation of the seal, loosen at (5) Apply 5 mm (0.20 in.) drop of Loctite 518, or
least the two main bearing caps forward of the rear equivalent, on each side of the rear main bearing cap
bearing cap. (Fig. 46). DO NOT over-apply sealant or allow the
(3) Rotate the new upper seal into the cylinder sealant to contact the rubber seal. Assemble bearing
block, being careful not to shave or cut the outer sur cap to cylinder block immediately after sealant appli
face of the seal. To ensure proper installation, use the cation.
installation tool provided with the kit. Install the (6) To align the bearing cap, use cap slot, align
new seal with the white paint facing toward the rear ment dowel, and cap bolts. DO NOT remove excess
of the engine. material after assembly. DO NOT strike rear cap
sit 3.9L ENGINE 9 - 45
HESiCWAL AND INSTALLATION (Continued)

(7) Install the rear main bearing cap with cleaned CYLINDER
and oiled cap bolts. Alternately tighten the cap bolts •-BLOCK ' /

or equivalent, at bearing cap-to-block joint to provide
cap to block and oil pan sealing. Apply enough seal
ant so that a small amount is squeezed out. With
draw nozzle and wipe excess sealant off the oil pan
seal groove.
ENGINE CORE OIL AND CAMSHAFT PLUGS

Engine core plugs have been pressed into the oil
galleries behind the camshaft thrust plate (Fig. 48).
This will reduce internal leakage and help maintain
higher oil pressure at idle. Fig. 49 Core Hole Plug Removal
(2) Using proper plug drive, drive cup plug into
hole. The sharp edge of the plug should be at least
0.50 mm (0.020 in.) inside the lead-in chamfer.
(3) I t is not necessary to wait for curing of the
sealant. The cooling system can be filled and the
vehicle placed in service immediately.
HYDRAULIC TAPPETS
CAUTION: The plunger and tappet bodies are not

interchangeable. The plunger and valve must
always be fitted to the original body. It is advisable
to work on one tappet at a time to avoid mixing of
parts. Mixed parts are not compatible. DO NOT dis
assemble a tappet on a dirty work bench.
Fig. 48 Location of Cup Plugs in Oil Galleries

DISASSEMBLE
MEMOWAL (1) Pry out plunger retainer spring clip (Fig. 50).
(1) Using a blunt tool such as a drift or a screw (2) Clean varnish deposits from inside of tappet
driver and a hammer, strike the bottom edge of the body above plunger cap.
cup plug (Fig. 49). (3) Invert tappet body and remove plunger cap,
(2) With the cup plug rotated, grasp firmly with plunger, check valve, check valve spring, check valve
pliers or other suitable tool and remove plug (Fig. retainer, and plunger spring (Fig. 50). Check valve
49). could be flat or ball.
INSTALLATION ASSEMBLE
Thoroughly clean inside of cup plug hole i n cylin (1) Clean all tappet parts in a solvent that will
der block or head. Be sure to remove old sealer. remove all varnish and carbon.
Be certain the new plug is cleaned of all oil or (2) Replace tappets that are unfit for further ser
grease. vice with new assemblies.
(1) Coat edges of plug and core hole with Mopar (3) I f plunger shows signs of scoring or wear,
Gasket Maker, or equivalent. install a new tappet assembly. I f valve is pitted, or
valve seat on end of plunger is prevented from seat
CAUTION: DO NOT drive cup plug Into the casting, ing, install a new tappet assembly.
as restricted coolant flow can result and cause seri (4) Assemble tappets (Fig. 50).
ous engine problems.
I - 46 3.91 ENGINE — BR
DISASSEMBLY AMD ASSEMBLY (Continued)
CHECK VALVE PLUNGER

SPRING CAP J9109-220
Fig. 50 Hydraulic Tappet Assembly
VALVES, GUIDES AND SPRINGS
WALWE CLEANING
Clean valves thoroughly. Discard burned, warped,
or cracked valves.
Fig. 52 Measuring Valve Guide Wear
Remove carbon and varnish deposits from inside of
valve guides with a reliable guide cleaner.
Reamer O/S Valve Guide Size
WALWE GUIDES
Measure valve stems for wear. I f wear exceeds 0.076 mm 8.026 - 8.052 mm
(0.003 in.) ( 0 . 3 1 6 - 0 . 3 1 7 in.)
0.051 mm (0.002 in.), replace the valve.
Measure valve stem guide clearance as follows: 0.381 mm 8.331 - 8 . 3 5 7 mm
• (1) Install Valve Guide Sleeve Tool C-3973 over (0.015 in.) (0.328 - 0.329 in.)
valve stem and install valve (Fig. 51). The special
sleeve places the valve at the correct height for
checking with a dial indicator.
J9309-30
Fig. 53 Reamer Sizes
• Step 1—Ream to 0.0763 mm (0.003 inch).
• ' Step 2—Ream to 0.381 mm (0.015 inch).
mEFACIMG WALWES AND WALWE SEATS

The intake and exhaust valves have a 43-1/4° to 43-3/4°
face angle and a 44-1/4° to 44-3/4° seat angle (Fig. 54).
WALWES
Inspect the remaining margin after the valves are
refaced (Fig. 55). Valves with less than 1.190 mm
Fig. 51 Positioning Valve with Tool C-3973
(0.047 in.) margin should be discarded.
(2) Attach dial indicator Tool C-3339 to cylinder
head and set i t at right angles to valve stem being WALWE SEATS
measured (Fig. 52).
(3) Move valve to and from the indicator. The total CAUTION: DO NOT un-shroud valves during valve
dial indicator reading should not exceed 0.432 mm seat refacing (Fig. 56).
(0.017 in.). Ream the guides for valves with oversize
stems i f dial indicator reading is excessive or i f the (1) When refacing valve seats, i t is important that
stems are scuffed or scored. the correct size valve guide pilot be used for reseat
ing stones. A true and complete surface must be
WALWE GUIDES obtained.
Service valves with oversize stems are available (2) Measure the concentricity of valve seat using a
(Fig.53). dial indicator. Total runout should not exceed 0.051
mm (0.002 in.) total indicator reading.
(1) Slowly turn reamer by hand and clean guide thor
oughly before installing new valve. Ream the valve (3) Inspect the valve seat with Prussian blue, to
guides from standard to 0.381 mm (0.015 in.). Use determine where the valve contacts the seat. To do
a two step procedure so the valve guides are this, coat valve seat LIGHTLY with Prussian blue
reamed true in relation to the valve seat: then set valve in place. Rotate the valve with light
en 3.9L ENGINE § - 47
D I S A S S E M B L Y AMD ASSEMBLY fContinued)
CONTACT
POINT c
REFACING STONE J>
457*° - 457<
A - SEAT WIDTH - INTAKE 1 . 0 1 6 - 1 . 5 2 4 mm (0.040 - 0.060 in.]

EXHAUST 1.524 - 2.032 mm (0.060 - 0.080 in.)
Fig. 56 Refacing Valve Seats
3
B - FACE ANGLE (INTAKE & EXHAUST) 4 3 7 / - 43 /<° VALVE SPRINGS
C - SEAT ANGLE (INTAKE & EXHAUST) 447*° - 447<°
D - CONTACT SURFACE Whenever valves have been removed for inspection,
reconditioning or replacement, valve springs should
J9309-95
be tested. As an example the compression length of
the spring to be tested is 1-5/16 in.. Turn table of
Fig. 54 Valve Face and Seat Angles Universal Valve Spring Tester Tool until surface is in
line with the 1-5/16 in. mark on the threaded stud.
Be sure the zero mark is to the front (Fig. 57). Place
spring over . stud on the table and lift compressing
INTAKE EXHAUST
lever to set tone device. Pull on torque wrench until
VALVE VALVE
ping is heard. Take reading on torque wrench at this
instant. Multiply this reading by 2. This will give the
spring load at test length. Fractional measurements
are indicated on the table for finer adjustments.
STEM" Refer to specifications to obtain specified height and
allowable tensions. Discard the springs that do not
meet specifications.
VALVE SPRING TORQUE
RETAINER LOCK WRENCH
GROOVE
J9209-127
Fig. 55 Intake and Exhaust Valves

pressure. I f the blue is transferred to the center of
valve face, contact is satisfactory. I f the blue is trans
VALVE SPRING
ferred to the top edge of valve face, lower valve seat TESTER
with a 15° stone. I f the blue is transferred to bottom
edge of valve face raise valve seat with a 60° stone.
(4) When seat is properly positioned the width of
intake seats should be 1.016-1.524 mm (0.040-0.060 9509-79
in.). The width of the exhaust seats should be 1.524-
2.032 mm (0.060-0.080 in.). Fig. 57 Testing Valve Spring for Compressed
Length
9 - 48 3 J L ENGINE
DISASSEMBLY A N P A S S E M B L Y fContinued)
OIL PUSVSP (4) Tap on a new retainer cap.

(5) Prime oil pump before installation by filling
DISASSEMBLE rotor cavity with engine oil.
( 1 ) Remove the relief valve as follows:
(a) Remove cotter pin. Drill a 8.175 mm (1/8 in.) CYLINDER BLOCI
hole into the relief valve retainer cap and insert a
self-threading sheet metal screw into cap. DISASSEMBLE
(b) Clamp screw into a vise and while support Engine assembly removed from vehicle:
ing oil pump, remove cap by tapping pump body (1) Remove the cylinder head.
using a soft hammer. Discard retainer cap and (2) Remove the oil pan.
remove spring and relief valve (Fig. 58). (3) Remove the piston and connecting rod assem
blies.
ASSEMBLE
(1) Install the piston and connecting rod assembly.
(2) Install the oil pan.
(3) Install the cylinder head,
(4) Install the engine into the vehicle.
G L E A M I M © Mm INSPECTION
C f L i i i E i HEAD COWER
CLEANING
Clean cylinder head cover gasket surface.
Clean head rail, i f necessary.
INSPECTION
Fig. 58 Oil Pressure Relief Valve Inspect cover for distortion and straighten, i f nec
(2) Remove oil pump cover (Fig. 5 9 ) . essary.
(3) Remove pump outer rotor and inner rotor with Check the gasket for use in head cover installation.
shaft (Fig. 59). If damaged, use a new gasket.
(4) , Wash all parts in a suitable solvent and inspect
carefully for damage or wear. CYLINDER HEAD
INNER ROTOR DISTRIBUTOR DRIVESHAFT
CLEANING
Clean all surfaces of cylinder block and cylinder
heads.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
INSPECTION
Inspect all surfaces with a straightedge i f there is
any reason to suspect leakage. I f out-of-flatness
exceeds 0.00075 mm/mm (0.00075 in./in.) times the
span length in any direction, either replace head or
EDGE RYlil lightly machine the head surface.
FOB, EXAMPLE:—A 305 mm (12 in.) span is
Fig, 59 Oil Pump 0.102 mm (0.004 in.) out-of-flat. The allowable out-of-
ASSEMBLE flat is 305 x 0.00075 (12 x 0.00075) equals 0.23 mm
(1) Install pump rotors and shaft, using new parts (0.009 in.). This amount of out-of-flat is acceptable.
as required. The cylinder head surface finish should be
(2) Position the oil pump cover onto the pump 1.78-3.00 microns (70-125 microinches).
body. Tighten cover bolts to 11 N-m (95 in. lbs.) Inspect push rods. Replace worn or bent rods.
torque.
(3) Install the relief valve and spring. Insert the
cotter pin.
C L E A N I N G ANP INSPECTION (Continued)

PISTON AND CONNECTING ROD INSPECTION OIL PUMP
Check the crankshaft connecting rod journal for
excessive wear, taper and scoring. OIL PUMP PRESSURE
Check the cylinder block bore for out-of-round, The MINIMUM oil pump pressure is 41.4 kPa (6
taper, scoring and scuffing. psi) at curb idle. The MAXIMUM oil pump pressure
Check the pistons for taper and elliptical shape is 207-552 kPa (30-80 psi) at 3,000 RPM or more.
before they are fitted Into the cylinder bore (Fig. 60).
CAUTION: If oil pressure is ZERO at curb idle, DO
PISTON PIN BORE DIAMETER NOT run engine at 3,000 RPM.
INSPECTION
Mating surface of the oil pump cover should be
smooth. Replace pump assembly i f cover is scratched
or grooved.
Lay a straightedge across the pump cover surface
(Fig. 61). I f a 0.038 mm (0.0015 in.) feeler gauge can
be inserted between cover and straightedge, pump
assembly should be replaced.
A
PISTON A DIA = PISTON DIAMETER BORE DIAMETER
A 99.280 (3.9087) 99.294 (3.9092) 99.306 (3.9097) 99.319(3.9102)
B 99.294 (3.9092) 99.306 (3.9097) 99.319(3.9102) 99.332 (3.9107)
c 99.306 (3.9097) 99.319(3.9102) 99.332 (3.9107) 99.344(3.9112)
D 99.319(3.9102) 99.332 (3.9107) 99:344(3.9112) 99.357(3.9117)
E 99.332 (3.9107) 99.344 (3.9112) 99.357 (3.9117) 99.370(3,9122) 8020cd6e
J9509-80
Fig. 61 Checking Oii Pump Cover Flatness
Measure thickness and diameter of outer rotor. I f
CRANKSHAFT INSPECTION OF JOURNALS outer rotor thickness measures 20.9 mm (0.825 in.)
The crankshaft connecting rod and main journals or less, or i f the diameter is 62.7 mm (2.469 in.) or
should be checked for excessive wear, taper or scor less, replace outer rotor (Fig. 62).
ing. The maximum taper or out-of-round on any
crankshaft journal is 0.025 mm (0.001 in.).
Journal grinding should not exceed 0.305 mm
(0.012 in.) under the standard journal diameter. DO
NOT grind thrust faces of No. 2 main bearing. DO
NOT nick crank pin or bearing fillets. After grinding,
remove rough edges from crankshaft oil holes and
clean out all oil passages.
CAUTION: After any journal grind, it is important

that the final paper or cloth polish be in the same
direction that the engine rotates.
Fig. 62 Measuring Outer Rotor Thickness


If inner rotor measures 20.9 mm (0.825 in.) or less,
replace inner rotor and shaft assembly (Fig. 63).
Fig. 65 Measuring Ciearance Between Rotors

Fig. 68 Measuring inner Rotor Thickness
Slide outer rotor into pump body. Press rotor to the
side with your fingers and measure clearance
between rotor and pump body (Fig. 64). I f clearance
is 0.356 mm (0.014 in.) or more, replace oil pump
assembly.
8020cd71
Fig. 66 Measuring Ciearance Over Rotors

34 mm (1-11/32 in.). Replace spring that fails to meet
these specifications (Fig. 67).
8020cd6f I f oil pressure was low and pump is within specifi
cations, inspect for worn engine bearings or other
' Fig. 64 Measuring Outer Rotor Ciearance in
reasons for oil pressure loss.
Housing
Install inner rotor and shaft into pump body. I f
clearance between inner and outer rotors is 0.203
mm (0.008 in.) or more, replace shaft and both rotors
(Fig. 65).
Place a straightedge across the face of the pump,
between bolt holes. I f a feeler gauge of 0.102 mm
(0.004 in.) or more can be inserted between rotors
and the straightedge, replace pump assembly (Fig.
66).
Inspect oil pressure relief valve plunger for scoring
and free operation in its bore. Small marks may be
removed with 400-grit wet or dry sandpaper.
The relief valve spring has a free length of approx RN98
imately 49.5 mm (1.95 in.). The spring should test
between 19.5 and,20.5 pounds when compressed to Fig. 67 Proper Installation of Retainer Cap
3 J L ENGINE I -11

OIL PAN I f plug is too high, use a suitable flat dowel to posi
tion properly.
CLEANING
RIGHT OIL GALLERY
Clean the block and pan gasket surfaces.
Trim or remove excess sealant film in the rear
main cap oil pan gasket groove. DO NOT remove
the sealant inside the rear m a i n cap slots.
CYLINDER
If present, trim excess sealant from inside the BLOCK
engine.
Clean oil pan in solvent and wipe dry with a clean
cloth.
Clean oil screen and pipe thoroughly in clean sol
vent. Inspect condition of screen. PLUG
OIL FROM FILTER
INSPECTION T O SYSTEM
Inspect oil drain plug and plug hole for stripped or
damaged threads. Repair as necessary.
Inspect oil pan mounting flange for bends or distor OIL T O FILTER
tion. Straighten flange, i f necessary. -
CYLINDER BLOCI
CLEANING J9209-147
CRANKSHAFT FROM OIL PUMP
Clean cylinder block thoroughly and check all core
hole plugs for evidence of leaking. Fig. 68 Oil Line Plug
INSPECTION (4) I f plug is too low, remove oil pan and No. 4
Examine block for cracks or fractures. main bearing cap. Use suitable flat dowel to position
The cylinder walls should be checked for out-of- properly. Coat outside diameter of plug with Mopar
round and taper with Cylinder Bore ' Indicator Tool Stud and Bearing Mount Adhesive, or equivalent.
C-119. The cylinder block should be bored and honed Plug should be 54.0 to 57.7 mm (2-1/8 to 2-5/16 in.)
with new pistons and rings fitted If: from bottom of the block.
• The cylinder bores show more than 0.127 mm
(0.005 in.) out-of-round.
• The cylinder bores show a taper of more than
0.254 mm (0.010 in.).
• The cylinder walls are badly scuffed or scored.
Boring and honing operation should be closely coor
dinated with the fitting of pistons and rings, so that
specified clearances can be maintained.
OIL LINE PLUi

The oil line plug is located in the vertical passage
at the rear of the block between the oil-to-filter and
oil-from-filter passages (Fig. 68). Improper Installa
tion or plug missing could cause erratic, low, or no oil
pressure.
The oil plug must come out the bottom. Use flat
dowel, down the oil pressure sending unit hole from
the top, to remove oil plug.
(1) Remove oil pressure sending unit from back of
block.
(2) Insert a 3.175 mm (1/8 In.) finish wire, or
equivalent, into passage.
(3) Plug should be 190.0 to 195.2 mm (7-1/2 to
7-11/16 in.) from machined surface of block (Fig. 68).
9 - 52 3.9L ENGINE -
SPECIFICATIONS
ENGINE SPECIFICATIONS
Camshaft
Bearing Diameter End Play 0.051-0.178 mm
No. 1 50.800-50.825 mm (0.002-0.007 in)
(2.000-2.001 in) Max. Allowable 0.254 mm
No. 2 . . 50.394-50.419 mm (0.010 in)
(1.984-1.985 in) Main Bearing Journals
No. 3 .. . . . . . . . . . . . . . . 49.606-49.632 mm Diameter 63.487-63.513 mm
(1.953-1.954 in) (2.4995-2.5005 in)
No. 4 39.688-39.713 mm Out-of-Round (Max.) 0.0254 mm
(1.5625-1.5635 in) (0.001 in)
Diametrical Clearance 0.0254-0.0762 mm Taper (Max.) 0.0254 mm
(0.001-0.003 in) (0.001 in)
Max. Allowable 0.127 mm
(0.005 in) Cylinder Block
End Play 0.051-0.254 mm Cylinder Bore
(0.002-0.010 in) Diameter 99.314-99.365 mm
Bearing Journal Diameter (3.910-3.912 in)
No. 1 . 50.749-50.775 mm Out-of-Round (Max.) 0.127 mm
(1.998-1.999 in) (0.005 in)
No. 2 50.343-50.368 mm Taper (Max.) 0.254 mm
(1.982-1.983 in) (0.010 in)
No. 3 . - 49.555-49.581 mm Oversize (Max.) 1.016 mm
(1.951-1.952 in) (0.040 in)
No. 4 39.637-39.662 mm Distributor Lower Drive Shaft
(1.5605-1.5615 in) Bushing (Press Fit in Block) . . . . 0.0127-0.3556 mm
(0.0005-0.0140 in)
Connecting Rods Shaft-to-Bushing Clearance 0.0178-0.0686 mm
Bearing Clearance 0.013-0.056 mm (0.0007-0.0027 in)
(0.0005-0.0022 in) Tappet Bore Diameter 22.99-23.01 mm
Max. Allowable 0.08 mm (0.003 in) (0.9051-0.9059 in)
Piston Pin Bore Diameter . . . . . . . . . . . 24.940-24.978 mm

Cylinder Head
(0.9819-0.9834 in) Compression Pressure . . . . . . . . . . . . . 689 kPa
Side Clearance (Two Rods) 0.152-0.356 mm (100 psi)
(0.006-0.014 in) Gasket Thickness (Compressed) . . . . . . 1.2065 mm
Total Weight (Less Bearing) 726 grams (0.0475 in)
(25.61 oz)
Valve Seat
Angle. . . . . . . . . . . . . . . . . . . . . . . . 44.25° - 44.75°
Crankshaft Runout (Max.) 0.0762 mm
Connect Rod Journal (0.003 in)
Diameter . . . . . . . . . . . . . . . . . . . . . 53.950-53.975 mm Width (Finish) - Intake . . . . . . . . . . . 1.016-1.542mm
(2.124-2.125 in) (0.040-0.060 in)
Out-of-Round (Max.) 0.0254 mm
Width (Finish) - Exhaust. . . . . . . . . . 1.524-2.032 mm
(0.001 in) (0.060-0.080 in)
Taper (Max.) 0.0254 mm
(0.001 in)
Hydraulic Tappets
B o d / Diameter 22.949-22.962 mm
Diametrical Clearance (0.9035-0.9040 in)
No. 1 0.013-0.038 mm Ciearance in Block 0.0279-0.0610 mm
(0.0005-0.0015 in) (0.0011-0.0024 in)
Nos. 2, 3, and 4 0.013-0.051 mm Dry Lash . . . . . . . . . . . . . . . . . . . 1.524-5.334 mm
(0.0005-0.0020 in) (0.060-0.210 in)
Max. Allowable (Nos. 2 3, <& 4) ............ 0.064 mm
F
Push Rod Length 175.64-176.15 mm
(0.0025 in)
(6.915-6.935 in)
J9509-65
BR — _ _ _ _ _ 3.9L ENGINE 9 - 53
Oil Pump Piston Pins

Clearance Over Rotors (Max.) . . . . . 0.1016 mm Clearance
(0.004 in) In Piston 0.00635-0.01905 mm
Cover Out-of-Flat (Max.) . . . . . . . . . 0.0381 mm (0.00025-0.00075 in)
(0.0015 in) In Rod (Interference) 0.0178-0.0356 mm
Inner Rotor Thickness (Min.) . . . . . . . 20.955 mm (0.0007-0.0014 in)
(0.825 in) Diameter . 24.996-25.001 mm
Outer Rotor (0.9841-0.9843 in)
Clearance (Max.) 0.3556 mm End Play . NONE
(0.014 in) Length . 75.946-76.454 mm
Diameter (Min.) 62.7126 mm (2.990-3.010 in)
(2.469 in)
Thickness (Min.) . . . . . . . . . . . . . . 20.955 mm Piston Rings
(0.825 in) Ring Gap
Tip Clearance Between Rotors (Max). . 0.2032 mm Compression Rings 0.254-0.508 mm
(0.008 in) (0.010-0.020 in)
Oil Control (Steel Rails) 0.254-1.270 mm
Oil Pressure (0.010-0.050 in)
At Curb Idle Speed (Minimum)*. . 41.4 kPa Ring Side Clearance
(6 psi) Compression Rings 0.038-0.076 mm
. At 3000 rpm 207-552 kPa (0.0015-0.0030 in)
(30-80 psi) Oil Ring (Steel Rails) 0.06-0.21 mm
Oil Pressure Switch (0.002-0.008 in)
Actuating Pressure (Min.) . . . . . . . 34.5-48.3 kPa Ring Width
(5-7 psi) Compression Rings 1.971-1.989 mm
(0.0776-0.0783 in)
* C A U T I O N : If pressure is ZERO at curb idle, Oil Ring (Steel Rails) 3.848-3.975 mm
DO NOT run engine at 3,000 rpm. (0.1515-0.1565 in)
Oil Filter Valves

Bypass Valve Setting .... 62-103 kPa Face Angle 43.25°-43.75°
(9-15 psi) Head Diameter
Intake 48.666 mm
Pistons (1.916 in)
Clearance at Top of Skirt 0.0127-0.0381 mm Exhaust 41.250 mm
(0.0005-0.0015 in) (1.624 in)
Land Clearance (Diametrical) . . . . . 0.635-1.016 mm Length (Overall)
(0.025-0.040 in) Intake . 124.28-125.92 mm
Piston Length 86.360 mm (4.893-4.918 in)
(3.40 in) Exhaust 124.64-125.27 mm
Piston Ring Groove Depth (4.907-4.932 in)
Nos. 1 and 2 4.572-4.826 mm Lift (Zero Lash) 10.973 mm
(0.180-0.190 in) (0.432 in)
No. 3 3.810-4.064 mm Stem Diameter 7.899-7.925 mm
(0.150-0.160 in) (0.311-0.312 in)
Weight 592.6-596.6 grams Stem-to-Guide Clearance . 0.0254-0.0762 mm
(20.90-21.04 oz) (0.001-0.003 in)
Max. Allowable (Rocking Method). . 0.4318 mm
(0.017 in)
Guide Bore Diameter (Std) . . . . . . . 7.950-7.976 mm
(0.313-0.314 in)
19509-67
ENGINE SPECIFICATIONS—CONT.
Valve Springs Valve Timing
Free Length (Approx.) 49.962 mm Exhaust Valve
(1.967 In) Closes (ATC) • 16°
Spring Tension . . . . . . . . . . . . . . . . . @ 41.66 mm = 378 N Opens (BBQ .............................. 5 2 °
{Valve Closed) (@ 1.64 in = 85 lbs) Duration 248°
Spring Tension @ 30.89 mm = 890 N Intake Valve
(Valve Open) (@ 1.212 in = 200 lbs) Closes (ABC) 50°
Number of Coils . . . . . . . . . . . . . . . 6.8 Ooens (BTC) 10°
Installed H e i g h t . . . . . . . . . . . . . . . . 41.66 mm Duration 240°
(Spring Seat to Retainer) (1.64 in) Valve Overlap 26°
Wire Diameter 4.50 mm
(0.177 in)
J9309-33
ENGINE SPECIFICATIONS—CONT
CONDITION IDENTIFICATION
CRANKSHAFT JOURNALS RorM Steel stamped (near notch) on no. 6 crankshaft

(UNDERSIZE) M-2-3 etc. (indicating no. 2 and 3 main bearing counterweight.
0.0254 mm (0.001 in.) journal)
and/or
R-1 -4 etc. (indicating no. 1 and 4 connecting rod
journal)
HYDRAULIC TAPPETS • Diamond-shaped stamp

(OVERSIZE) Top pad - front of engine and flat ground on
0.2032 mm (0.008 in.) outside surface of each O / S tappet bore.
VALVE STEMS (OVERSIZE) X Milled pad adjacent to two tapped holes

0.127 mm (0.005 in.) (3/8 in.) on each end of cylinder head.
J930S-81
OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS

B R — 3 J L ENGINE §- ii
SPECIFICATIONS (Continued!
DESCRIPTION TORQUE DESCRIPTION TORQUE
Adjusting Strap Bolt 23 N*m (200 in. lbs.) Rear Insulator-to-Bracket

Through-Bolt 68 N«m (50 ft. lbs.)
Camshaft Bolt 68 N*m (50 ft. lbs.) Rear Insulator-to-Crossmember
Camshaft Thrust Plate Bolts 24 N*m (210 in. lbs.) Support Bracket Nut 41 N*m (30 ft. lbs.)
Chain Case Cover Bolts 41 N»m (30 ft. lbs.) Rear Support Bracket-to-Crossmember
Connecting Rod Cap Bolts 61 N*m (45 ft. lbs.) Flange Nuts 41 N«m (30 ft. lbs.)
Crankshaft Main Bearing Cap Bolts... 115 N»m (85 ft. lbs.) Rocker Arm Bolts 28 N«m (21 ft. lbs.)
Cylinder Head Bolts
1 st Step 68 N*m (50 ft. lbs.) Spark Plugs 41 N*m (30 ft. lbs.)
2nd Step 1 4 3 N * m ( 1 0 5 ft. lbs.) Starter Mounting Bolts 68 N*m (50 ft. lbs.)
Cylinder Head Cover Bolts 11 N»m (95 in. lbs.)
Thermostat Housing Bolts 25 N«m (225 in. lbs.;
Exhaust Manifold-to-Cylinder Throttle Body Bolts 23 N*m (200 in. lbs.;
Head Bolts/Nuts 34 N*m (25 ft. lbs.; Torque Converter Drive Plate Bolts 31 N«m (270 in. lbs.;
Transmission Support
Flywheel Bolts 75 N«m (55 ft. lbs.) Bracket Bolts 68 N«m (50 ft. lbs.)
Front Insula ted Attaching Bolts 41 N»m (30 ft. lbs.) Transmission Support Spacer-to-
Front Insulator Stud Nuts 102 N«m (75 ft. lbs.) Insulator Mounting Plate Nuts (4WD)... 204 N«m (150 ft. lbs.)
Front Mount Adaptor-to-Block Bolts 41 N«m (30 ft. lbs.)
Vibration Damper Retainer Bolt 183 N»m (1 35 ft. lbs.)
Generator Mounting Bolt 41 N*m (30 ft. lbs.)
Water Pump-to-Chain Case
Intake Manifold Bolts Refer to Procedure in Cover Bolt. 41 N»m (30 ft. lbs.)
Service Manual.
Oil Pan Bolts 24 N®m (215 in. lbs.;

Oil Pan Drain Plug 34 N*m (25 ft. lbs.)
Oil Pump Attaching Bolts 41 N«m (30 ft. lbs.)
Oil Pump Cover Bolts 11 N*m (95 in. lbs.)
J9509-70
TORQUE SPECIFICATIONS
9 - 56 3.9L ENGINE -
SPECIAL TOOLS
3.9L ENGINE
Valve Spring Compressor MD-998772-A Dial Indicator C-3339
Adapter 6633 Puller C-3688

3.9L ENGINE I -
SPECIAL T O O L S Continued)
Front Oil Seal installer 8635 Distributor Bushing Driver/Burnisher C-3053
80l1d423
Cam Bearing Remover/lnstailer C-3132-A Piston Ring Compressor C-385
Camshaft Holder C-3509 Crankshaft Main Bearing Remover C-3059
80l1c9fci
Distributor Bushing Puller C-3Q52 Cylinder Bore Gauge C-119

9 - 58 5.2L ENGINE
INDEX
page page
G E N E R A L INFORMATION FRONT CRANKSHAFT OIL SEAL . 77

OIL PUMP PRESSURE 5 8 HYDRAULIC TAPPETS 69
PISTON AND CONNECTING ROD ASSEMBLY . . 58 OIL PAN . . . . . . . . . 75
VALVES AND VALVE SPRINGS 58 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
DESCRIPTION AND OPERATION PISTON AND CONNECTING ROD ASSEMBLY . . 75
ENGINE COMPONENTS . '. . . . . 61 ROCKER ARMS AND PUSH RODS . . . . . . 67
GENERAL INFORMATION . 58 TIMING CHAIN COVER 70
LUBRICATION SYSTEM . . . . . . . . . . . . . . . 59 TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . 71
SERVICE PROCEDURES VALVE SPRING AND STEM SEAL
CRANKSHAFT MAIN BEARINGS . . . 63 REPLACEMENT-SN VEHICLE . . 67
CRANKSHAFT . . . . . 64 VALVES AND VALVE SPRINGS . . . . . . . . . 69
FITTING CONNECTING ROD BEARINGS 63 VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . . . 69
FITTING PISTON RINGS 62 DISASSEMBLY AND ASSEMBLY
FITTING PISTONS . . . . . . . . . . . . . . 62 CYLINDER BLOCK ...... . . . . 83
MEASURING TIMING CHAIN STRETCH . . . . . . . 61 HYDRAULIC TAPPETS 80
VALVE TIMING 61 OIL PUMP 82
REMOVAL AND INSTALLATION VALVE SERVICE . . . . . . . . . . . . . . . . . . . . 81
CAMSHAFT . . . . . . . . . . . . . . 72 CRANKSHAFT INSPECTION OF JOURNALS . . . 83
CRANKSHAFT MAIN BEARINGS . . . 73 CYLINDER BLOCK 85
CRANKSHAFT REAR OIL SEALS 77 CYLINDER HEADS . . . . . . 83
CRANKSHAFT 76 OIL PAN . . . . . . . . . . . . . . . . . . 83
CYLINDER HEAD COVER 67 OIL PUMP 84
CYLINDER HEADS 68 PISTON AND CONNECTING ROD ASSEMBLY . . 83
DISTRIBUTOR DRIVE SHAFT BUSHING 74 SPECIFICATIONS
ENGINE ASSEMBLY 65 5.2L ENGINE SPECIFICATIONS . . . . . . . . . . . . . 87
ENGINE CORE OIL AND CAMSHAFT PLUGS . . 79 SPECIAL TOOLS
ENGINE FRONT MOUNTS . . , . 64 5.2L ENGINE 91
ENGINE REAR MOUNT 64
M I N E R A L I i .. . across the thrust face. This allows for expansion

under normal operating conditions. Under operating
VALVES AND VALVE SPRINGS temperatures, expansion forces the pin bosses away
The valves are arranged in-line and inclined 18°. from each other, causing the piston to assume a more
The rocker pivot support and the valve guides are nearly round shape.
cast integral with the heads. All pistons are machined to the same weight,
The MINIMUM oil pump pressure is 41.4 k?a (6 retained by the press interference fit of the piston
z
CAUTION: If oil pressure is Z E R O at curb idie, DO

^mmwp :mm Asm mmwimmm
GENERAL l l F O i l M I O i
The 5 . 2 Liter (318 CID) eight-cylinder engine is a
PISTON AND CONNECTING ROD ASSEMBLY V-Type lightweight, single cam, overhead valve
diameter at the pin boss is less than its diameter This engine is designed for unleaded fuel.
mm — 5.21 ENGINE I - 51
PESCRlPTiOlf AND OPERATION (Continued)
Engine Type 90° V-8 OHV X M 5.2L T XXXX XXXXXXXX

lore and Stroke ...99.3 x 840 mm {3.91 x 3.31 in.)
Displacement 5.21 (318 cu. in.)
Compression Ratio .9.1:1 X = Last Digit of Model Year
Torque .....407 N«m (3001, lbs.) # 3,200 rpm M = Plant - M Mound Road
Firing Order ..................................1-8-4-3-6-5-7-2 S Saltillo
Lubrication ......Pressure Feed - Full Flow Filtration • T Trenton
Engine Oil Capacity 4.7L (5.0 Qts) with Filter K Toluca
Cooling System Liquid Cooled - Forced Circulation 5.2L = Engine Displacement
Coding Canity.........................................16.1 L (17.0 Qts) T = Usage - T Truck
Cylinder Block... .......Cast Iron XXXX = Month/Day
Crankshaft ..Nodular Iron XXXXXXXX = Serial Code - Last 8 Digits of VIN No.
Cylinder Head ..................Cast Iron
Combustion Chambers Wedge-High Swirl Valve Shrouding
J9209-73
Camshaft........ Nodular Cast Iron
Pistons Aluminum Alloy w/Strut
Fig. 3 Engine identification Number
cap. The pump draws oil through the screen and
inlet tube from the sump at the rear of the oil pan.
The oil is driven between the drive and idler gears
J9409-10
and pump body, then forced through the outlet to the
block. An oil gallery in the block channels the oil to
Fig. 1 Engine Description
the inlet side of the full flow oil filter. After passing
Engine lubrication system consists of a rotor type through the filter element, the oil passes from the
oil pump and a full flow oil filter. center outlet of the filter through an oil gallery that
The cylinders are numbered from front to rear; 1, channels the oil up to the main gallery which
3, 5, 7 on the left bank and 2, 4, 6 , 8 on the right extends the entire length on the right side of the
bank. The firing order is 1-8-4-3-6-5-7-2 (Fig. 2). block. The oil then goes down to the No. 1 main bear
ing, back up to the left side of the block and into the
lery to the upper shell of each main bearing. The
Each connecting rod bearing has half a hole in it, oil
rotates. This oil throw off lubricates the camshaft
ton pins.
The hydraulic valve tappets receive oil directly
J908D-49
receive oil from the main bearing galleries. The front
camshaft bearing journal passes oil through the cam
Fig. 2 Firing Order shaft sprocket to. the timing chain. Oil drains back to
the oil pan under the number one main bearing cap.
The engine serial number is stamped into a The oil supply for the rocker arms and bridged
machined pad located on the left, front corner of the pivot assemblies is provided by the hydraulic valve
cylinder block. When component part replacement is tappets which pass oil through hollow push rods to a
necessary, use the engine type and serial number for hole in the corresponding rocker arm. Oil from the
reference (Fig. 3). rocker arm lubricates the valve train components.
The oil then passes down through the push rod guide
LUBRICATION SYSTEM holes, and the oil drain back passages in the cylinder
A gear—type positive displacement pump is head past the valve tappet area, and returns to the
mounted at the underside of the rear main bearing oil pan.
D
m
BOLT m
OIL D E F L E C T O R R O C K E R ARM 0
TAB PIVOT R O C K E R ARM 2
1
ROCKER H
OIL SUPPLY ARM
FROM HOLLOW TO MAIN
PUSH ROD BEARINGS
DRIP OILING HOLLOW
FOR VALVE TIP PUSH ROD o
0
1
m
CYLINDER HEAD
TAPPET 39
BOSS
OIL SUPPLY VIA
HOLLOW PUSH ROD
>
SUPPLY IS FROM OIL
G A L L E R Y METERED THROUGH
o
HYDRAULIC TAPPET o
3
#•»>
OIL PASSAGE FOR OIL 5"
P R E S S U R E INDICATOR LIGHT c
a
RIGHT OIL G A L L E R Y
PASSAGE
TO CAMSHAFT
REAR BEARING

PLUG TO SYSTEM ROD BEARINGS
CRANKSHAFT

DESCRIPTION AND O P E R A T I O N ( C o n t i n u e d !
ENGINE COMPONENTS now read from 10° before top dead center to 2° after
top dead center. Remove spacer.
CYLINDER HEAD
The alloy cast iron cylinder heads (Fig. 5) are held CAUTION: DO NOT turn crankshaft any further
in place by 1 0 bolts. The spark plugs are located in clockwise as valve spring might bottom and result
the peak of the wedge between the valves. in serious damage.
The 5.2L cylinder head is identified by the foundry
mark NH. If reading is not within specified limits:
• Check sprocket index marks.
EXHAUST SPARK EXHAUST SPARK EXHAUST • Inspect timing chain for wear.
VALVE PLUGS VALVES PLUGS VALVE
• Check accuracy of DC mark on timing indicator.
MEASURING TIMING CHAIN STRETCH
NOTE: To access timing chain Refer to Timing

Chain Cover in Removal and Installation Section.

any movement of the chain may be measured.
(2) Place a torque wrench and socket over cam
shaft sprocket attaching bolt. Apply torque i n the
INTAKE INTAKE N-m (30 ft. lbs.) torque with cylinder head installed
VALVES VALVES J9309-37 or 20 N-m (15 ft. lbs.) torque with cylinder head
removed. With a torque applied to the camshaft
Fig. 5 Cylinder Head Assembly sprocket bolt, crankshaft should not be permitted to
PISTONS move. I t may be necessary to block the crankshaft to
All pistons are machined to the same weight, prevent rotation.
regardless of size, to maintain piston balance. (3) Hold a scale with dimensional reading even
The pistons are elliptically turned so that the with the edge of a chain link. With cylinder heads
diameter at the pin boss is less than its diameter installed, apply 14 N-m (30 ft. lbs.) torque in the
across the thrust face. This allows for expansion reverse direction. With the cylinder heads removed,
under normal operating conditions. Under operating apply 20 N-m (15 ft. lbs.) torque in the reverse direc
temperatures, expansion forces the pin bosses away tion. Note the amount of chain movement (Fig. 6).
from each other, causing the piston to assume a more
nearly round shape.
The piston pin rotates i n the piston only and is
retained by the press interference fit of the piston
pin in the connecting rod.
SERVICE P R O C E D U R E S
VALVE THING
( 1 ) Turn crankshaft until the No.6 exhaust valve is
closing and No.6 intake valve is opening.
(2) Insert a 6.350 mm (1/4 inch) spacer between Fig. 6 Measuring Timing Chain Wear and Stretch
rocker arm pad and stem tip of No.l intake valve.
Allow spring load to bleed tappet down giving in (4) Install a new timing chain, i f its movement
effect a solid tappet. exceeds 3.175 mm (1/8 inch).
(3) Install a dial indicator so plunger contacts (5) I f chain is not satisfactory, remove camshaft
valve spring retainer as nearly perpendicular as pos sprocket attaching bolt and remove timing chain with
sible. Zero the indicator. crankshaft and camshaft sprockets.
(4) Rotate the crankshaft clockwise (normal run (6) Place both camshaft sprocket and crankshaft
ning direction) until the valve has lifted 0.863 mm sprocket on the bench with timing marks on exact
(0.034 inch). The timing of the crankshaft should imaginary center line through both camshaft and
crankshaft bores.
9 - 32 5.2L ENGINE
SEHWiCE PftOCEBtfRES (Continued)

(8) Turn crankshaft and camshaft to line up with PISTON PIN BORE DIAMETER
shaft sprocket.
A
Fig. 7 Alignment of Timing Marks PISTON A DIA = PISTON DIAMETER BORE DIAMETER
SIZE MIN. mm (IN.) < MAX. mm (IN.) MIN. mm (IN.) M A I . mm (IN.)
(11) Install the camshaft bolt. Tighten the bolt to A 99.280 (3.9087) 99.294 (3.9092) 99.306 (3.9097) 99.319(3.9102)
47 N-m (35 f t . lbs.) torque. B 99.294 (3,9092) 99,306 (3.9097) 99.319(3.9102) 99.332 (3.9107)
(12) Check camshaft end play. The end play should C 99.306 (3.9097) 99.319(3.9102) 99.332 (3.9107) 99.344(3,9112)
be 0.051-0.152 m m (0.002-0.006 inch) with a new D 99.319(3.9102) 99,332 (3,9107) 99.344(3.9112) 99.357 (3.9117)
E 99,332 (3.9107) 99.344 (3.9112) 99.357(3.9117) 99.370(3.9122)
thrust plate a n d up to 0.254 mm (0.010 inch) with a
J9509-80
used thrust plate. I f not within these limits install a
new thrust plate.
FITTING PISTONS (c) Rings with insufficient end gap may be prop
Piston a n d cylinder w a l l must be clean and dry. erly filed to the correct dimension. Rings with,
Specified clearance between the piston and the cylin excess gaps should not be used.
der w a l l is 0.013-0.038 m m (0.0005-0.0015 inch) at (2) Install rings and confirm ring side clearance:
21°C (70°F). (a) Install oil rings being careful not to nick or
Piston diameter should be measured at the top of scratch the piston. Install the oil control rings
skirt, 90° to piston pin axis location A in (Fig. 8). Cyl according to instructions in the package, i t is not
inder bores should b e measured halfway down the necessary to use a tool to install the upper and
cylinder bore and transverse to the engine crankshaft lower rails. Insert oil rail spacer first, then side
center' line. rails.
Pistons and cylinder bores should be measured at (b) Install the second compression rings using
normal room temperature, 2PC (70°F). Installation Tool C-4184. The compression rings
must be installed with the identification mark face
FITTING PISTON ilNGS up (toward top of piston) and chamfer facing down.
(1) Measurement o f end gaps: An identification mark on the ring is a drill point,
a
(a) Measure piston ring gap 2 inches from bot a stamped letter O", an oval depression or the
tom o f cylinder bore. An inverted piston can be word TOP (Fig. 9) (Fig. 11).
u s e d t o p u s h t h e rings d o w n t o ensure positioning (c) Using a ring installer, install the top com
rings squarely i n t h e cylinder bore before measur pression ring with the chamfer facing up (Fig. 10)
ing. (Fig. 11), An identification mark on the ring is a
(b) Insert feeler gauge i n t h e g a p . The top com drill point, a stamped letter "O", an oval depression
pression ring g a p should be between. 0.254-0.508 or the word TOP facing up.
mm (0.010-0.020 inch). The second compression (d) Measure side clearance between piston ring
ring gap should be between 0.508-0.762 m m (0.020- and ring land. Clearance should be 0.074-0.097 mm
0.030 i n c h ) . T h e o i l ring g a p should be 0.254-1.270 (0.0029-0.0038 inch) for the compression rings. The
m m (0.010-0.050 i n c h ) . steel rail oil ring should be free in groove, but
5.2L ENGINE S - 83
should not exceed 0.246 mm (0.0097 inch) side OIL RING

SPACER GAP
clearance.
(e) Pistons with insufficient or excessive side
SECOND C O M P R E S S I O N R I N G CHAMFER SECOND
is, (BLACK CAST [RON) COMPRESSION
TOP
\ RING G A P
COMPRESSION
" OIL RING RAIL
RING G A P
G A P (TOP)
OIL RING RAIL

TWO
DOTS J9009-46
Pig. 11 PfGyCk Ring Installation
Fig. § Second Compression Ring identification The bearing caps are not interchangeable and
(Typical) should be marked at removal to ensure correct
assembly.
TOP COMPRESSION RING Each bearing cap has a small V-groove across the
(GRAY IN COLOR) parting face. When installing the lower bearing shell,
make certain that the V-groove in the shell is in line
CHAMFER with the V-groove in the cap. This provides lubrica
tangs are in the machined grooves in the rods and
caps. . •
Limits of taper or out-of-round on any crankshaft
journals should be held to 0.025 mm (0.001 inch).
Bearings' are available in 0.025 mm (0.001 inch),
J9G0SM8 0.051 mm (0.002 inch),, 0.076 mm (0.003 inch), 0.254
Fig. 10 Top Compression Ring Identification mm (0.010 inch) and 0.805 mm (0.012 inch) under
(Typical) size. Install the bearings i n pairs. DO NOT use a
new bearing half w i t h an old bearing half* ID'C-
CHAMFER TOP C O M P R E S S I O N NOT file t h e rods or bearing caps.
RING
\
CRANK: MAIN BEARINGS

Bearing caps are not interchangeable and should
Upper and' lower bearing halves are NOT inter
SECOND changeable. Lower' main bearing halves of No.2 and 4
;Oi/#RESSiON
RING
Upper and lower No.3 bearing halves are flanged
to carry the crankshaft thrust loads. They are NOT
CHAMFER
PISTON J9409-37 interchangeable with any other bearing halves in the
engine (Fig. 13). Bearing shells are available in stan
Fig, 11 Compression Ring Chamfer Location dard and the following undersizes: 0.25 mm (0.001
(Typical) inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch),
FITTING CONNECTING ROD BEAIEiGS 0.254 mm (0.010 inch) and 0.305 mm (0.012 inch).
Never install an undersize bearing that will reduce
Fit all rods on a bank until completed. DO NOT
clearance below specifications.
alternate from one bank to another, because connect
one bank to another.
9 - 84 5.2L ENGINE
S E R V I C E PROCEDURES (Continued)
R E M @ i a i i m m INSTALLATION
UPPER
ENGINE F R 0 I T MOUNTS
REMOVAL
(2) Position fan to assure clearance for radiator top
tank and hose.
CAUTION; DO NOT lift the engine by the intake

manifold.
LOWER
J9309-83 (5) Lift the engine SLIGHTLY and remove the
thru-bolt and nut (Fig. 15).
• Fig. 13 Main Bearing identification (6) Remove engine support bracket/cushion bolts
(Fig. 15). Remove the support bracket/cushion and
CRANKSHAFT . heat shields.
A crankshaft which has undersize journals will be
stamped with 1/4 inch letters on the milled flat on ENGINE MOUNT
the No.8 crankshaft counterweight (Fig. 14). HEAT SHIELD
FOE EXAMPLE: R2 stamped on the No.8 crank
shaft counterweight indicates that the No.2 rod jour ENGINE SUPPORT
nal is 0.025 mm (0.001 in) undersize. M4 indicates BRACKET/CUSHION
that the No.4 main journal is 0.025 mm (0.001 in)

undersize. R3 M2 indicates that the No.3 rod journal
and the No.2 main journal are 0.025 mm (0.001 in) THRU-BOLT
undersize.
Undersize Journal Identification Stamp
0.025 mm (0.001 in.) (Rod) R1-R2-R3 or R4

RESTRICTION PADS
0.025 mm (0.001 in.) (Main) M1-M2-M3-M4 or M5
J9409-144
#8 CRANKSHAFT R-l -2-<—(ROD) Fig. 15 Engine Front Mounts

COUNTERWEIGHT ^ ÊRS'"' M-l •<—(MAIN)
INSTALLATION
n (1) With engine raised SLIGHTLY, position the

engine support bracket/cushion and heat shields to
-- the block. Install new bolts and tighten to 81 N-m (60
ft. lbs.) torque.
(2) Install the thru-bolt into the engine support
-J9209-13c
bracket/cushion.
(3) Lower engine with support/lifting fixture while
Fig. 14 Location of Crankshaft identification guiding the engine bracket/cushion and thru-bolt into
support cushion brackets (Fig. 16).
When a crankshaft is replaced, all main and con
(4) Install thru-bolt nuts and tighten the nuts to
necting ' rod bearings should be replaced with new
replaced. (6) Remove lifting fixture.
ENGINE REM! MOUNT
REMOVAL
(1) Raise the vehicle on a hoist.
(2) Position a transmission jack in place.
(5) Remove the bolts holding the support cushion
to the transmission support bracket. Remove the sup
port cushion.
(6) I f necessary, remove the bolts holding the
transmission support bracket to the transmission.
ENGINE INSTALLATION
SUPPORT (1) I f removed, position the transmission support
BRACKET/ bracket to the transmission. Install new attaching
CUSHION
bolts and tighten to 102 N-m (75 ft. lbs.) torque.
(2) Position support cushion to transmission sup
port bracket. Install stud nuts and tighten to 47 N-m
(3) Using the transmission jack, lower the trans
mission and support cushion onto the crossmember
(Fig. 17).
(4) Install the support cushion bolts and tighten to
SUPPORT (5) Remove the transmission jack.
CUSHION (6) Lower the vehicle.
BRACKET
J9409-54
ENGINE ASSEMBLY
Fig. 16 Positioning Engine Front Mounts
REMOVAL
(3) Remove support cushion stud nuts (Fig. 17). (1) Remove the battery.
(4) Raise rear of transmission and engine (2) Drain cooling system (refer to Group 7, Cooling
SLIGHTLY. System for the proper procedure).

9 - 66 5.2L ENGINE

(3) Remove the upper crossmember and top core (37) Install an engine lifting fixture.
support. (38) Remove engine from vehicle and install
(4) Remove the transmission oil cooler. engine assembly on a repair stand.
equipped (refer to Group 24, Heating and Air Condi INSTALLATION
tioning for service procedures). (1) Remove engine from the repair stand and posi
(6) Remove the serpentine belt (refer to Group 7, tion in the engine compartment. Position the thru-
Cooling System). bolt into the support cushion brackets.
(7) Remove the A/C compressor with the lines (2) Install an engine support fixture.
attached. Set aside. (3) Raise and support the vehicle on a hoist.
(8) I f equipped, remove the condenser. (4) Refer to Group, 21 Transmissions for transmis
(9) Remove the washer bottle. sion installation
(10) Disconnect the top radiator hose. (5) Install rear transmission support.
(11) Remove the fan. (6) Install the prop shaft (refer to Group 16, Pro
(12) Remove the fan shroud. peller Shaft).
(13) Disconnect the lower radiator hose. (7) Install the dust shield and transmission cover.
(14) Remove radiator (refer to Group 7, Cooling (8) Install the starter and connect the starter
System). wires (refer to Group 8B, Battery/Starter/Generator
(15) Remove the generator with the wire connec Service).
tions (refer to Group 8B, Battery/Starter/Generator (9) Install exhaust pipe to manifold.
Service). (10) Install the transmission cooler line brackets
(16) Remove the air cleaner box. from oil pan.
(17) Disconnect the throttle linkage. (11) Install engine front mount thru-bolt nuts.
(18) Remove throttle body. Tighten the nuts.
(19) Remove the intake manifold (refer to Group (12) Install the drain plug and tighten to 34 N-m
11, Exhaust System and Intake Manifold). (25 ft. lbs.) torque.
(20) Remove the distributor cap and wiring. (13) Lower the vehicle.
(21) Disconnect the heater hoses. (14) Remove engine lifting fixture.
(22) Disconnect the power steering hoses, i f (15) On Manual Transmission vehicles, install the
equipped. shift lever (refer to Group 21, Transmissions).
(23) Disconnect the transmission cooler lines. (16) Connect the fuel lines.
(24) Perform the Fuel System Pressure Release (17) Connect the transmission cooler lines.
procedure (refer to Group 14, Fuel System). (18) Connect the power steering hoses, i f equipped.
(25) Disconnect the fuel lines. (19) Connect the heater hoses.
(26) On Manual Transmission vehicles, remove the (20) Install the distributor cap and wiring.
shift lever (refer to Group 21, Transmissions). (21) Install the intake manifold (refer to Group 11,
(27) Raise and support the vehicle on a hoist. Exhaust System and Intake Manifold).
(28) Remove the drain plug and drain the engine (22) Using a new gasket, install throttle body.
oil. Tighten the throttle body bolts to 23 N-m (200 in.
(29) Remove engine front mount thru-bolt nuts. lbs.) torque.
(30) Remove the transmission cooler line brackets (23) Connect the throttle linkage.
from oil pan. (24) Install the air cleaner box.
(31) Disconnect exhaust pipe at manifold. (25) Install the generator and wire connections
(32) Disconnect the starter wires. Remove starter (refer to Group 8B, Battery/Starter/Generator Ser
motor (refer to Group 8B, Battery/Starter/Generator vice).
Service). (26) Install radiator (refer to Group 7, Cooling Sys
(33) Remove the dust shield and transmission tem).
cover. (27) Connect the lower radiator hose.
(34) Refer to group 21, Transmissions for trans (28) Install the fan shroud.
mission removal. (29) Install the fan.
(35) Remove the prop shaft (refer to Group 16, (30) Connect the top radiator hose.
Propeller Shaft). (31) Install the washer bottle.
(36) Lower the vehicle. (32) I f equipped, install the condenser.
(33) Install the A/C compressor with the lines
CAUTION: D O NOT lift the engine by the intake attached.
manifold. (34) Install the serpentine belt (refer to Group 7,
Cooling System).

(35) Evacuate and charge the air conditioning sys ROCKER ARMS AND PUSH RODS
tem, i f equipped (refer to Group 24, Heating and Air
Conditioning for service procedures). REMOVAL
(36) Install the transmission oil cooler. (1) Disconnect spark plug wires by pulling on the
(37) Install the upper crossmember and top core boot straight out in line with plug.
support. (2) Remove cylinder head cover and gasket.
(38) Add coolant to the cooling system (refer to (3) Remove the rocker arm bolts and pivots (Fig.
Group 7, Cooling System for the proper procedure). 19). Place them on a bench in the same order as
(39) Install the battery. removed.
(40) Warm engine and adjust. (4) Remove the push rods and place them on a
(41) Road test vehicle. bench in the same order as removed.
ROCKER CYLINDER
CYLINDER HEAD COVER
NOTE: A steel backed silicon gasket is used with

the cylinder head cower (Fig, 18). This gasket can
be used again.
CYLINDER HEAD
COVER GASKET V
J9209-65
Fig. * 19 Rocker Arms

INSTALLATION
(1) Rotate the crankshaft until the "V8" mark lines
J9209-105
cover. This mark is located 147° ATDC from the No.l
firing position.
Fig. 18 Cylinder Head Cover Gasket
(2) Install the push rods in the same order as
REMOVAL removed.
(1) Disconnect the negative cable from the battery. (3) Install rocker arm and pivot assemblies in the
(2) Disconnect closed ventilation system and evap same order as removed. Tighten the rocker arm bolts
oration control system from cylinder head cover. to 28 N-m (21 ft. lbs.) torque.
(3) Remove cylinder head cover and gasket. The
gasket may be used again. CAUTION: DO NOT rotate or crank the engine dur
ing or immediately after rocker arm installation.
NOTE: CLEANING Allow the hydraulic roller tappets adequate time to
Clean cylinder head cover gasket surface. bleed down (about 5 minutes).
Clean head rail, if necessary.
INSPECTION (4) Install cylinder head cover.
Inspect cover for distortion and straighten, if nec (5) Connect spark plug wires.
essary.
Check the gasket for use in head cover installa ¥AL¥E SPRING AND STE1 SEAL REPLACEMENT-
tion. If damaged, use a n e w gasket. IN VEHICLE
(1) Set engine basic timing to Top Dead Center
(TDC).
INSTALLATION
(1) The cylinder head cover gasket can be used
(3) Remove cylinder head covers and spark plugs.
again. Install the gasket onto the head rail.
(4) Remove coil wire from distributor and secure to
good ground to prevent engine from starting.
ket. Tighten the bolts to 11 N-m (95 in. lbs.) torque.
(5) Using suitable socket and flex handle at crank
(3) Install closed crankcase ventilation system and
shaft retaining bolt, turn engine so the N o . l piston is
evaporation control system.
at TDC on the compression stroke.
(6) Remove rocker arms.
(7) With air hose attached to an adapter installed (19) Remove spark plugs.
in No.l spark plug hole, apply 620-689 kPa (90-100
psi) air pressure. INSTALLATION
(8) Using Valve Spring Compressor Tool (1) Clean all surfaces of cylinder block and cylin
MD-998772A with adaptor 6633, compress valve der heads.
spring and remove retainer valve locks and valve (2) Clean cylinder block front and rear gasket sur
spring. faces using a suitable solvent.
(9) Install seals on the exhaust valve stem and (3) Position the new cylinder head gaskets onto
position down against valve guides. the cylinder block.
(10) The intake valve stem seals should be pushed (4) Position the cylinder heads onto head gaskets
firmly and squarely over the valve guide using the and cylinder block.
valve stem as a guide. DO NOT force seal against top (5) Starting at top center, tighten all cylinder head
of guide. When installing the valve retainer locks, bolts, in sequence, to 68 N-m (50 ft. lbs.) torque (Fig.
compress the spring only enough to install the locks. 20). Repeat procedure, tighten all cylinder head bolts
(11) Follow the same procedure on the remaining 7 to 143 N-m (105 ft. lbs.) torque. Repeat procedure to
cylinders using the firing sequence 1-8-4-3-6-5-7-2. confirm that all bolts are at 143 N-m (105 ft. lbs.)
Make sure piston in cylinder is at TDC on the valve torque.
spring that is being removed.
(12) Remove adapter from the No.l spark plug
hole.
(14) Install covers and coil wire to distributor.
(15) Install air cleaner.
CYLINDER HE1DS
REMOVAL
(2) Drain cooling system (refer to Group 7, Cooling
System for the proper procedures).
(3) Remove the intake manifold-to-generator
(4) Remove closed crankcase ventilation system. Fig. 20 Cylinder Head Bolt Tightening Sequence
(5) Disconnect the evaporation control system. CAUTION: When tightening the rocker arm bolts,
(6) Remove the air cleaner. make sure the piston in that cylinder is NOT at
(7) Perform the Fuel System Pressure Release pro TDC. Contact between the valves and piston could
cedure (refer to Group 14, Fuel System). Disconnect occur.
the fuel lines.
(8) Disconnect accelerator linkage and i f so (6) Install push rods and rocker arm assemblies in
equipped, the speed control and transmission kick- their original position. Tighten the > bolts to 28 N-m
down cables. (21 ft. lbs.) torque.
(9) Remove the return spring. (7) Install the intake manifold and throttle body
(10) Remove distributor cap and wires. assembly (refer to Group 11, Exhaust System and
(11) Disconnect the coil wires. Intake Manifold).
(12) Disconnect heat indicator sending unit wire. (8) Install exhaust manifolds. Tighten the bolts
(13) Disconnect heater hoses and bypass hose. and nuts to 34 N-m (25 ft. lbs.) torque.
(14) Remove cylinder head covers and gaskets. (9) Adjust spark plugs to specifications (refer to
(15) Remove intake manifold and throttle body as Group 8D, Ignition System). Install the plugs and
an assembly. Discard the flange side gaskets and the tighten to 41 N-m (30 ft. lbs.) torque.
front and rear cross-over gaskets. (10) Install coil wires.
(16) Remove exhaust manifolds. (11) Connect heat indicator sending unit wire.
(17) Remove rocker arm assemblies and push rods. (12) Connect the heater hoses and bypass hose.
Identify to ensure installation in original locations. (13) Install distributor cap and wires.
(18) Remove the head bolts from each cylinder (14) Hook up the return spring.
head and remove cylinder heads. Discard the cylin
der head gasket.
BR 1.2L E N G I N E I - II

(15) Connect the accelerator linkage and i f so top of spacer. I f height is greater than 42.86 mm
equipped, the speed control and transmission kick- (1-11/16 Inches), install a 1.587 mm (1/16 inch)
down cables. spacer in head counterbore. This should bring spring
(16) Install the fuel lines. height back to normal 41.27 to 42.86 mm (1-5/8 to
(17) Install the generator and drive belt. Tighten 1-11/16 inch).
generator mounting bolt to 41 N-m (30 ft. lbs.)
torque. Tighten the adjusting strap bolt to 23 N-m HYDRAULIC TAPPETS
(200 in. lbs.) torque. Refer to Group 7, Cooling Sys
tem for adjusting the belt tension. REMOVAL
(18) Install the intake manifold-to-generator (1) Remove the air cleaner.
bracket support rod. Tighten the bolts. (2) Remove cylinder head cover.
(19) Place the cylinder head cover gaskets i n posi (3) Remove rocker assembly and push rods. Iden
tion and install cylinder head covers. Tighten the tify push rods to ensure installation In original loca
bolts to 11 N-m (95 in. lbs.) torque. tion.
(20) Install closed crankcase ventilation system. (4) Remove Intake manifold.
(21) Connect the evaporation control system. (5) Remove yoke retainer and aligning yokes.
(22) Install the air cleaner. (6) Slide Hydraulic Tappet Remover/Installer Tool
(23) Install the heat shields. Tighten the bolts to C-4129-A through opening in cylinder head and seat
41 N-m (30 ft. lbs.) torque. tool firmly In the head of tappet.
(24) Fill cooling system (refer to Group 7, Cooling (7) Pull tappet out of bore with a twisting motion.
System for proper procedure). If all tappets are to be removed, Identify tappets to
(25) Connect the negative cable to the battery. ensure installation in original location.
(8) I f the tappet or bore i n cylinder block is scored,
¥AL¥ES AND ¥AL¥E SPIiNIS scuffed, or shows signs of sticking, ream the bore to
REMOVAL
(1) Remove the cylinder head. INSTALLATION
(2) Compress valve springs using Valve Spring (1) Lubricate tappets.
Compressor Tool MD- 998772A. (2) Install tappets and push rods in their original
(3) - Remove valve retaining locks, valve spring positions. Ensure that the oil feed hole In the side of
retainers, valve stem seals and valve springs. the tappet body faces up (away from the crankshaft).
(4) Before removing valves, remove any burrs from (3) Install aligning yokes with ARROW toward
valve stem lock grooves to prevent damage to the camshaft.
valve guides. Identify valves to ensure installation i n (4) Install yoke retainer. Tighten the bolts to 23
original location. N-m (200 in. lbs.) torque. Install intake manifold.
(5) Install push rods in original positions.
INSTALLATION (6) Install rocker arm.
(1) Clean valves thoroughly. Discard burned, (7) Install cylinder head cover.
warped and cracked valves. (8) Start and operate engine. Warm up to normal
(2) Remove carbon and varnish deposits from operating temperature.
inside of valve guides with a reliable guide cleaner.
(3) Measure valve stems for wear. I f wear exceeds CAUTION; To prevent damage to valve mechanism,
0.051 mm (0.002 Inch), replace the valve. engine must not be run above fast idle until all
(4) Coat valve stems with lubrication oil and insert hydraulic tappets have filled with oil and have
them in cylinder head. become quiet.
(5) I f valves or seats are reground, check valve
stem height. I f valve is too long, replace cylinder
head. ¥IBRATI0N DAMPER .
(6) Install new seals on all valve guides. Install
REMOVAL
valve springs and valve retainers.
(7) Compress valve springs with Valve Spring (1) Disconnect the negative cable from the battery.
Compressor Tool MD-998772A, Install locks and (2) Remove fan shroud retainer bolts and set
release tool. I f valves and/or seats are ground, mea shroud back over engine.
sure the Installed height of springs. Make sure the (3) Remove the cooling system' fan.
measurement is taken from bottom of spring seat In (4) Remove the serpentine belt (refer to Group 7,
cylinder head to the bottom surface of spring Cooling System).
retainer. I f spacers are Installed, measure from the (5) Remove the vibration damper pulley.
9 - 70 5,21 ENGINE BR

(6) Remove vibration damper bolt and washer from ( 2 ) Drain cooling system (refer to Group 7 , Cooling
end of crankshaft. System).
( 7 ) Install bar and screw from Puller Tool Set ( 3 ) Remove the serpentine belt (refer to Group 7 ,
C-3688. install 2 bolts with washers through the Cooling System).
puller tool and into the vibration damper (Fig. 2 1 ) . ( 4 ) Remove water pump (refer to Group 7, Cooling
System).
( 5 ) Remove power steering pump (refer to Group
1 9 , Steering).
( 6 ) Remove vibration damper.
( 7 ) Loosen oil pan bolts and remove the front bolt
at each side.
( 9 ) Remove chain case cover and gasket using
( 1 0 ) Place a suitable tool behind the lips of the oil
J9209-81 seal to pry the oil seal outward. Be careful not to
damage the crankshaft seal surface of cover (Fig. 2 3 ) .
Fig. 21 Vibration Damper Assembly
(8) Pull vibration damper off of the crankshaft.
INSTALLATION
(1) Position the vibration damper onto the crank
shaft.
(2) Place installing tool, part of Puller Tool Set
C-3688 in position and press the vibration damper
onto the crankshaft (Fig. 2 2 ) .

INSTALLATION
( 1 ) Be sure mating surfaces of chain case cover
( 2 ) The water pump mounting surface must be
cleaned.
( 3 ) Using a new cover gasket, carefully install
chain case cover to avoid damaging oil pan gasket.
Use a small amount of Mopar® Silicone Rubber Adhe
Fig. 22 Installing Vibration Damper sive Sealant, or equivalent, at the joint between tim
(3) Install the crankshaft bolt and washer. Tighten ing chain cover gasket and the oil pan gasket. Finger
the bolt to 183 N-m (135 ft. lbs.) torque. tighten the timing chain cover bolts at this time.
(4) Install the crankshaft pulley. Tighten the pul ( 4 ) Place the smaller diameter of the oil seal over
ley bolts to 23 N-m (200 in. lbs.) torque. Front Oil Seal Installation Tool 6 6 3 5 (Fig. 2 4 ) . Seat
(5) Install the serpentine belt (refer to Group 7, the oil seal in the groove of the tool.
Cooling System). ( 5 ) Position the seal and tool onto the crankshaft
(6) Install the cooling system fan. Tighten the (Fig. 25).
bolts to 2 3 N-m ( 1 7 ft. lbs.) torque. ( 6 ) Tighten the 4 lower chain case cover bolts to
(7) Position the fan shroud and install the bolts. 13N-m ( 1 0 ft.lbs.) to prevent the cover from tipping
Tighten the retainer bolts to 1 1 N-m ( 9 5 in. lbs.) during seal installation.
torque. ( 7 ) Using the . vibration damper bolt, tighten the
bolt to draw the seal into position on the crankshaft
(8) Connect the negative cable to the battery. (Fig. 26).
(8) Loosen the 4 bolts tightened in step 4 to allow
TIMING CHAIN COVER realignment of front cover assembly.
MEMOWAL
( 1 ) Disconnect the negative cable from the battery.
5.2L ENGINE § - 71
J9309-46
Fig. 26 installing Oil Seal

(17) Position the fan shroud and Install the bolts.
Tighten the bolts to 11 N-m (95 In. lbs.) torque.
(18) Fill cooling system (refer to Group 7, Cooling
System for the proper procedure).
(19) Connect the negative cable to the battery/
THING CHAIN
REMOVAL
(1) Remove Timing Chain Cover Refer to proce
dure In this section.
(2) Remove camshaft sprocket attaching bolt and
COVER J9309-45*- remove timing chain with crankshaft and camshaft
sprockets.
Fig, 25 Position Toot and Seat onto Crankshaft
(9) Tighten chain case cover bolts to 41 N-m (30 INSTALLATION
ft.lbs.) torque. Tighten oil pan bolts to 24 N-m (215 (1) Place both camshaft sprocket and crankshaft
in. lbs.) torque. sprocket on the bench with timing marks on exact
(10) Remove the vibration damper bolt and seal Imaginary center line through both camshaft and
installation tool. crankshaft bores.
(11) Inspect the seal flange on the vibration (2) Place timing chain around both sprockets.
damper. (3) Turn crankshaft and camshaft to line up with
(12) Install vibration damper. keyway location in crankshaft sprocket and in cam
(13) Install water pump and housing assembly shaft sprocket.
using new gaskets (refer to Group 7, Cooling Sys (4) Lift sprockets and chain (keep sprockets tight
tem). Tighten bolts to 41 N-m (30 ft. lbs.) torque. against the chain in position as described).
(14) Install power steering pump (refer to Group (5) Slide both sprockets evenly over their respec
19, Steering). tive shafts and use a straightedge to check alignment
(15) Install the serpentine belt (refer to Group 7, of timing marks (Fig. 27).
Cooling System). (6) install the camshaft bolt. Tighten the bolt to 68
Fig.. 27 Alignment of Timing Marks

be 0.051-0.152 mm (0.002-0.006 inch) with a new
thrust plate and up to 0.254 mm (0.010 inch) with a
new thrust plate.
CAMSHAFT
NOTE: The camshaft has an integral oil pump and

distributor drive gear (Fig. 28). Fig. 29 Timing Chain Oil Tab Installation
NOTE: Whenever an engine has been rebuilt, a new
camshaft and/or new tappets installed, add 1 pint of
Mopar Crankcase Conditioner, or equivalent. The oil
mixture should be left in engine for a minimum of
805 km (500 miles). Drain at the next normal oil
change.
(2) Install Camshaft Gear Installer Tool C-3509

with tongue back of distributor drive gear (Fig. 30).
J9309-71
Fig. 28 Camshaft and Sprocket Assembly

MEMOWML
(1) Remove intake manifold.
(2) Remove cylinder head covers.
(3) Remove timing case cover and timing chain.
(5) Remove push rods and tappets. Identify each
part so i t can be installed i n its original location.
(6) Remove distributor and lift out the oil pump
and distributor drive shaft.
(7) Remove camshaft thrust plate, note location of Fig. 30 Camshaft Holding Tool C-3509 (Installed
oil tab (Fig. 29). Position)
(8) Install a long bolt into front of camshaft to
facilitate removal of the camshaft. Remove camshaft, (3) Hold tool in position with a distributor lock-
being careful not to damage cam bearings with the plate bolt. This tool will restrict camshaft from being
cam lobes. pushed in too far and prevent knocking out the welch
plug i n rear of cylinder block. Tool should remain
INSTALLATION installed until the camshaft and crankshaft
(1) Lubricate camshaft lobes and camshaft bearing sprockets and timing chain have been installed.
journals and insert the camshaft to within 51 mm (2 (4) Install camshaft thrust plate and chain oil tab.
inches) of its final position i n cylinder block. Make sure tang enters lower right hole in
thrust plate. Tighten bolts to 24 N-m (210 in. lbs.)
REMOVAL AND I N S T A L L A T I O N f C o n t i n u e d !
torque. Top edge of tab should be flat against thrust
plate in order to catch oil for chain lubrication.
sprocket on the bench with timing marks on exact
imaginary center line through both camshaft and
crankshaft bores.
(7) Turn crankshaft and camshaft to line up with
shaft sprocket.
(9) Slide both sprockets evenly over their respec Fig. 32 Camshaft Bearings Removal/Installation with
tive shafts and use a straightedge to check alignment Tool C-3132-A
of timing marks (Fig. 31). (2) Position rear bearing in the tool. Install horse
shoe lock and by reversing removal procedure, care
Fig. 31 Alignment of Timing Marks REMOVAL

(10) Install the camshaft bolt/cup washer. Tighten (1) Remove the oil pan.
bolt to 68 N-m (50 ft. lbs.) torque. (2) Remove the oil pump from the rear main bear
(11) Measure camshaft end play. Refer to Specifica ing cap.
tions for proper clearance. I f not within limits install (3) Identify bearing caps before removal. Remove
a new thrust plate. bearing caps one at a time.
(12) Each tappet reused must be installed in the (4) Remove upper half of bearing by inserting
same position from which it was removed. When Crankshaft Main Bearing Remover/Installer Tool
camshaft is replaced, all of the tappets must be C-3059 into the oil hole of crankshaft (Fig. 33).
replaced. (5) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.
CAMSHAFT BEARINGS
INSTALLATION
REMOVAL Only one main bearing should be selectively fitted
NOTE: This procedure requires that the engine is ened. A l l bearing capbolts removed during service
removed from the vehicle. procedures are to be cleaned and oiled before instal
lation.
(1) With engine completely disassembled, drive out When installing a new upper bearing shell, slightly
rear cam bearing core hole plug. chamfer the sharp edges from the plain side.
(2) Install proper size adapters and horseshoe (1) Start bearing in place, and insert Crankshaft
washers (part of Camshaft Bearing Remover/Installer Main Bearing Remover/Installer Tool C-3059 into oil
Tool C-3132-A) at back of each bearing shell. Drive hole of crankshaft (Fig. 33).
out bearing shells (Fig. 32). (2) Slowly rotate crankshaft counterclockwise slid
INSTALLATION (3) Install the bearing caps. Clean and oil the
(1) Install new camshaft bearings with Camshaft bolts. Tighten the capbolts to 115 N-m (85 ft. lbs.)
Bearing Remover/Installer Tool C-3132-A by sliding torque.
the new camshaft bearing shell over proper adapter. (4) Install the oil pump.
SPECIAL SPECIAL TOOL If B E A R I N G .

TOOL C - 3 0 5 9
Fig. 35 Distributor Driveshaft Bushing Installation

CAUTION: This procedure MUST be followed when
installing a new bushing or seizure to shaft may
9209-59 occur.
Fig, 33 Upper Main i wing Removal and

..
Installation with Tool C-3059

DISTRIBUTOR DRIVE SHAFT BUSHING
REMOVAL
(1) Remove distributor, refer to Group 8D, Ignition
Systems for the proper procedure.
(2) Remove the intake manifold (refer to Group 11,
Exhaust System and Intake Manifold). J9209-87
(3) Insert Distributor Drive Shaft Bushing Puller
Tool C-3052 into old bushing and thread down until a Fig. 36 Burnishing Distributor Driveshaft Bushing
tight fit is obtained (Fig. 34).
(4) Hold puller screw and tighten puller nut until (4) Install the intake manifold (refer to Group 11,
bushing is removed. Exhaust System and Intake Manifold).
DISTRIBUTOR INSTALLATION
NOTE: Before installing the distributor, the oil

pump drive shaft must be aligned to number one
cylinder.
(1) Rotate crankshaft until No.l cylinder is at top

dead center on the firing stroke.
(2) When in this position, the timing mark of
vibration damper should be under "0" on the timing
indicator.
Fig. 34 Distributor Driveshaft Bushing Removal (3) Install the shaft so that after the gear spirals
into place, i t will index with the oil pump shaft. The
INSTALLATION slot on top of oil pump shaft should be aligned
(1) Slide new bushing over burnishing end of Dis towards the left front intake manifold attaching bolt
tributor Drive Shaft Bushing Driver/Burnisher Tool hole (Fig. 37).
C-3053. Insert the tool and bushing into the bore. (4) Install distributor, refer to Group 8D, Ignition
(2) Drive bushing and tool into position, using a Systems for the proper procedure.
hammer (Fig. 35). After the distributor has been installed, its rota
(3) As the burnisher is pulled through the bushing, tional position must be set using the S E T SYNC
the bushing is expanded tight in the block and bur mode of the DRB scan tool. Refer to Checking Dis
nished to correct size (Fig. 36). DO NOT ream this tributor Position following the Distributor Installa
bushing. tion section i n Group 8D, Ignition system.
Do not attempt to adjust ignition timing by
rotating the distributor. It has no effect on igni-
BR 5.2L ENGINE S - 75
REMOVAL A N D INSTALLATION (Continued}
Fig. 37 Position of Oil Pump Shaft Slot

Hon timing. Adjusting d i s t r i b u t o r position w i l l
effect fuel synchronization only.
OIL PAN
REMOVAL
(2) Remove engine oil dipstick.
(3) Raise vehicle.
(4) Drain engine oil. Fig. 39 Position of Dowels in Cylinder Block
(5) Remove exhaust pipe.
(6) Remove left engine to transmission strut. (6) Apply small amount of Mopar® Silicone Rubber
(7) Loosen the right side engine support bracket Adhesive Sealant, or equivalent in the corner of the
cushion thru-bolt nut and raise the engine slightly. cap and the cylinder block.
Remove oil pan by sliding backward and out. (7) Slide the one-piece gasket over the dowels and
(8) Remove the one-piece gasket. onto the block.
(8) Position the oil pan over the dowels and onto
INSTALLATION the gasket.
(1) Clean the block and pan gasket surfaces. (9) Install the oil pan bolts. Tighten the bolts to 24
(2) Trim or remove excess sealant film i n the rear N-m (215 in. lbs.) torque.
main cap oil pan gasket groove. DO NOT remove (10) Remove the dowels. Install the remaining oil
the sealant inside the rear main cap slots. pan bolts. Tighten these bolts to 24 N-m (215 in. lbs.)
(3) I f present, trim excess sealant from inside the torque.
engine. (11) Lower the engine into the support cushion
(4) Fabricate 4 alignment dowels from 5/16 x 1 1/2 brackets and tighten the thru bolt nut to the proper
inch bolts. Cut the head off the bolts and cut a slot torque.
into the top of the dowel. This will allow easier (12) Install the drain plug. Tighten drain plug to
installation and removal with a screwdriver (Fig. 38). 34 N-m (25 ft. lbs.) torque.
(13) Install the engine to transmission strut.
5 / 1 6 " x VI" BOLT (14) Install exhaust pipe.
(15) Lower vehicle.
(16) Install dipstick.
y DOWEL
PISTON AND CONNECTING ROD ASSE1BLY
A REMOVAL
SLOT J9509-163 (1) Remove the engine from the vehicle.
(2) Remove the cylinder head.
Fig. 38 Fabrication of Alignment Dowels (3) Remove the oil pan.
(5) Install the dowels in the cylinder block (Fig. (4) Remove top ridge of cylinder bores with a reli
39). able ridge reamer before removing pistons from cyl-
I - 76 5.21 ENGINE mm
inder block. Be sure to keep tops of pistons covered of the connecting rod bore must be installed toward
during this operation. crankshaft journal fillet.
(5) Be sure the connecting rod and connecting rod (8) Install rod caps. Be sure connecting rod, con
cap are identified with the.cylinder number. Remove necting rod cap and cylinder bore number are the
connecting rod cap. Install connecting rod bolt guide same. Install nuts on cleaned and oiled rod bolts and
set on connecting rod bolts. tighten nuts to 61 N-m (45 ft. lbs.) torque.
(6) Pistons and connecting rods must be removed (9) Install the oil pan.
from top of cylinder block. When removing piston and (10) Install the cylinder head.
connecting rod assemblies, rotate crankshaft to cen (11) Install the engine into the vehicle.
ter the connecting rod in the cylinder bore and at
BDC. Be careful not to n i c k crankshaft journals, CRANKSHAFT
(7) After removal, install bearing cap on the mat
ing rod. REMOVAL
INSTALLATION (2) Remove the oil pump from the rear main bear
(1) Be sure that compression ring gaps are stag ing cap.
gered so that neither is in-line with oil ring rail gap. (3) Remove the vibration damper.
(2) Before installing the ring compressor, make (4) Remove the timing chain cover.
sure the oil ring expander ends are butted and the (5) Identify bearing caps before removal. Remove
rail gaps located properly (Fig. 40). bearing caps and bearings one at a time.
OIL RING
(6) Lift the crankshaft out of the block.
SPACER GAP (7) Remove and discard the crankshaft rear oil
seals.
(8) Remove and discard the front crankshaft oil
seal.
SECOND
COMPRESSION INSTALLATION
TOP
COMPRESSION
RING GAP (1) Clean Loctite 518 residue and sealant from the
OIL RING RAIL cylinder block and rear cap mating surface. Do this
RING GAP
GAP (TOP)
before applying the Loctite drop and the installation
of rear cap.
oil.
OIL RING RAIL the white paint facing towards the rear of the engine.
GAP (BOTTOM) J9309-80 (4) Position the crankshaft into the cylinder block.
Fig. 40 Proper Ring installation
oil.
(3) Immerse the piston head and rings In clean (6) Install the new lower rear bearing oil seal into
engine oil. Slide Piston Ring Compressor Tool C-385 the bearing cap with the white paint facing towards
over the piston and tighten with the special wrench the rear of the engine.
(part of Tool C-385). Be sure position of rings . (7) Apply 5 mm (0.20 in) drop of Loctite 518, or
does not change d u r i n g this operation. equivalent, on each side of the rear main bearing cap
(4) Install connecting rod bolt protectors on rod (Fig. 41). DO NOT over apply sealant or allow the
bolts, the long protector should be installed on the sealant to contact the rubber seal. Assemble bearing
numbered side of the connecting rod. cap to cylinder block immediately after sealant appli
(5) Rotate crankshaft so that the connecting rod cation.
journal is on the center of the cylinder bore. Be sure (8) To align the bearing cap, use cap slot, align
connecting rod and cylinder bore number are the ment dowel and cap bolts. DO NOT remove excess
same. Insert rod and piston Into cylinder bore and material after assembly. DO NOT strike rear cap
.guide rod over the crankshaft journal. more than 2 times for proper engagement.
(6) Tap the piston down in cylinder bore, using a (9) Clean and oil all cap bolts. Install all main
hammer handle. At the same time, guide connecting bearing caps. Install all cap bolts and alternately
rod into position on crankshaft journal. tighten to 115 N-m (85 ft. lbs.) torque.
(7) The notch or groove on top of piston must be (10) Install oil pump.
pointing toward front of engine. The larger chamfer (11) Install the timing chain cover.
(12) Install the vibration damper.
, MOPAR SILICONE RUBBER ADHESIVE SEALANT SLOTS pump attaching bolts. Tighten attaching bolts to 41
.^LOCTITE 515 (OR EQUIVALENT) N-m (30 ft. lbs.) torque.
T T (3) Install the oil pan.
FRONT CRANKSHAFT OIL SEAL

The oil seal can be replaced without removing the
timing chain cover provided the cover is not mis
o CAP aligned.
ST
ALIGNMENT. (1) Disconnect the negative cable from the battery.
SLOT
o . REAR MAIN "

(3) I f front seal is suspected of leaking, check front
oil seal alignment to crankshaft. The seal installa
tion/alignment tool 6635, should fit with minimum
interference. I f tool does not fit, the cover must be
removed and installed properly.
Fig. 41 Sealant Application to Bearing Cap seal to pry the oil seal outward. Be careful not to
(13) Apply Mopar® Silicone Rubber Adhesive Seal damage the crankshaft seal bore of cover.
ant, or equivalent, at bearing cap to block joint to (5) Place the smaller diameter of the oil seal over
provide cap to block and oil pan sealing (Fig. 42). Front Oil Seal Installation Tool 6635 (Fig. 43). Seat
Apply enough sealant until a small amount is the oil seal in the groove of the tool.
squeezed out. Withdraw nozzle and wipe excess seal CRANKSHAFT k • INSTALL THIS
ant off the oil pan seal groove. FRONT OIL END INTO
(14) Install new front crankshaft oil seal. SEAL SPECIAL TOOL
6635
(15) Immediately Install the oil pan.
SEALANT
NOZZLE TIP
^ J9309-44

REAR MAIN • (6) Position the seal and tool onto the crankshaft
BEARING CAP J9309-87 (Fig. 44).
(7) Using the vibration damper bolt, tighten the
Fig. 42 Apply Sealant to Bearing Cap to Block Joint bolt to draw the seal into position on the crankshaft
OIL PUMP (Fig. 45).
(8) Remove the vibration damper bolt and seal
REMOVAL installation tool.
(1) Remove the oil pan. (9) Inspect the seal flange on the vibration
(2) Remove the oil pump from rear main bearing damper.
cap. (10) Install the vibration damper.
INSTALLATION
(1) Install oil pump. During installation slowly CRANKSHAFT REAR OIL SEALS
rotate pump body to ensure driveshaft-to-pump rotor The service seal is a 2 piece, viton seal. The upper
shaft engagement. seal half can be installed with crankshaft removed
(2) Hold the oil pump base flush against mating from engine or with crankshaft installed. When a
surface on No.5 main bearing cap. Finger tighten new upper seal is installed, install a new lower seal.
R E M O V A L A H © I N S T A L L A T I O N fContinued)
INSTALLATION
face. Make sure the seal groove-is free of debris.
oil
(5) Lightly oil the new lower seal Hps with engine
oil.
the rear of the engine.
(7) Apply 5 mm (0.20 in) drop of Loctite 518, or
(Fig. 46). DO NOT over apply sealant or allow the
sealant to contact the rubber seal. Assemble bearing
cation.
Fig. 44 Position Tool and Seal onto Crankshaft

ment dowel and cap bolts. DO NOT remove excess
material after * assembly. DO NOT strike rear cap
more than 2 times for proper engagement.
(9) Clean and oil all cap bolts. Install all main
bearing caps. Install all cap bolts and alternately
J9309-46
Fig. 45 Installing Oil Seal (11) Apply Mopar Silicone Rubber Adhesive Seal
ant, or equivalent, at bearing cap to block joint to
The lower seal half can only be installed with the
provide cap to block and oil pan sealing (Fig. 47).
rear main bearing cap removed.
Apply enough sealant until a small amount is
UPPER SEAL —CRANKSHAFT REMOVED squeezed out. Withdraw nozzle and wipe excess seal
ant off the oil pan seal groove.
REMOVAL (12) Install new front crankshaft oil seal.
(1) Remove the crankshaft. Discard the old upper (13) Immediately install the oil pan.
seal.
mm 5.2L ENGINE I - 79
MOPAR SILICONE SEALANT (7) Install the rear main bearing cap with cleaned
RUBBER ADHESIVE APPLIED and oiled cap bolts. Alternately tighten ALL pap bolts
or equivalent, at bearing cap to block joint to provide
cap to block and oil pan sealing (Fig. 47). Apply
enough sealant until a small amount Is squeezed out.
pan seal groove.
LOWER SEAL
REiOWAL
Fig, 47 Apply Sealant to Bearing Cap to Block Joint (2) Remove the oil pump from the rear main bear
UPPER SEAL —CRANKSHAFT INSTALLED ing cap.
(3) Remove the rear main bearing cap and discard
R E 1 0 W A L the old lower seal.
(2) Remove the oil pump from the rear main bear INSTALLATION
ing cap. (1) Clean the rear main cap mating surfaces
(3) Remove the rear main bearing cap. Remove including the oil pan gasket groove.
and discard the old lower oil seal. (2) Carefully install a new upper seal (refer to
(4) Carefully remove and discard the old upper oil Upper Seal Replacement - Crankshaft Installed pro
seal. cedure above).
INSTALLATION oil.
(1) Clean the cylinder block mating surfaces before (4) Install a new lower seal in bearing cap with
oil seal Installation. Check for burr at the oil hole on the white paint facing the rear of engine.
the cylinder block mating surface to rear cap. (5) Apply 5 mm (0.20 In) drop of Loctite 518, or
(2) Lightly oil the new upper seal lips with engine equivalent, on each side of the rear main bearing cap
oil. To allow ease of installation of the seal, loosen at (Fig. 46). DO NOT over apply sealant or allow the
least the 2 main bearing caps forward of the rear sealant to contact the rubber seal. Assemble bearing
bearing cap. cap to cylinder block immediately after sealant appli
(3) Rotate the new upper seal Into the cylinder cation.
block being careful not to shave or cut the outer sur (6) To align the bearing cap, use cap slot, align
face of the seal. To assure proper installation, use the ment dowel and cap bolts. DO NOT remove excess
installation tool provided with the kit. Install the material after assembly. DO NOT strike rear cap
new seal with the white paint facing towards the more than 2 times for proper engagement.
rear of the engine. (7) Install the rear main bearing cap with cleaned
(4) Install the new lower rear bearing oil seal Into and oiled cap bolts. Alternately tighten the cap bolts
the bearing cap with the white paint facing towards to 115 N-m (85 ft. lbs.) torque.
the rear of the engine. (8) Install oil pump.
(5) Apply 5 mm (0.20 in) drop of Loctite 518, or (9) Apply Mopar Silicone Rubber Adhesive Sealant,
equivalent, on each side of the rear main bearing cap or equivalent, at bearing cap to block joint to provide
(Fig. 46). DO NOT over apply sealant or allow the cap to block and oil pan sealing (Fig. 47). Apply
sealant to contact the rubber seal. Assemble bearing enough sealant until a small amount is squeezed out.
cap to cylinder block Immediately after sealant appli Withdraw nozzle and wipe excess sealant off the oil
cation. Be sure the white paint faces toward the rear pan seal groove.
of the engine. (10) Immediately Install the oil pan.
ment dowel and cap bolts. DO NOT remove excess ENGINE CORE OIL AND CAMSHAFT PLUGS
material after assembly. DO NOT strike rear cap Engine core plugs have been pressed into the oil
more than 2 times for proper engagement. galleries behind the camshaft thrust plate (Fig. 48).
9 - 80 5,21 ENGINE
R E M O V A L AND INSTALLATION ( C o n t i n u e d )
This will reduce internal leakage and help maintain CAUTION: DO NOT drive cup plug into the casting,
higher oil pressure at idle. as restricted coolant flow can result and cause seri
ous engine problems.

0.50 mm (0.020 in.) inside the lead-in chamfer.
(3) I t is not necessary to wait for curing of the
sealant. The cooling system can be filled and the
vehicle placed in service immediately.
DISASSEMBLY AUB ASSEMBLY
HYDRAULIC TAPPETS
CAUTION: The plunger and tappet bodies are not

Fig, 48 Location of Cup Piugs in Oii Galleries
REMOVAL DISASSEMBLE
(1) Using a blunt tool such as a drift or a screw (1) Pry out plunger retainer spring clip (Fig. 50).
driver and a hammer, strike the bottom edge of the (2) Clean varnish deposits from inside of tappet
cup plug (Fig. 49). body above plunger cap.
(2) With the cup plug rotated, grasp firmly with (3) Invert tappet body and remove plunger cap,
pliers or other suitable tool and remove plug (Fig. plunger, check valve, check valve spring, check valve
49). retainer and plunger spring (Fig. 50). Check valve
CYLINDER could be flat or ball.
^ BLOCK ^ /
ASSEMBLE
(1) Clean all tappet parts in a solvent that will
remove all varnish and carbon.
(2) Replace tappets that are unfit for further ser
vice with new assemblies.
(3) I f plunger shows signs of scoring or wear,
install a new tappet assembly. I f valve is pitted, or
ing, install a new tappet assembly.
(4) Assemble tappets (Fig. 50).
DRIFT 9209-41
Fig. 49 Core Hole Plug Removal

INSTALLATION
Thoroughly clean inside of cup plug hole in cylin
der block or head. Be sure to remove old sealer.
SPWNG CAP J9109-220
Be certain the new plug is cleaned of all oil or
grease.
Fig. 50 Hydraulic Tappet Assembly
(1) Coat edges of plug and core hole with Mopar
Gasket Maker, or equivalent.
VALVE SERVICE
Reamer O/S Valve Guide Size
VALVE GUIDES
0.076 mm 8.026 - 8.052 mm
Measure valve stem guide clearance as follows:
(0.003 in.) ( 0 . 3 1 6 - 0 . 3 1 7 in.)
(1) Install Valve Guide Sleeve Tool C-3973 over
valve stem and install valve (Fig. 51). The special 0.381 mm 8.331 - 8.357 mm
sleeve places the valve at the correct height for (0.015 in.) ( 0 . 3 2 8 - 0 . 3 2 9 in.)
checking with a dial indicator.
J9309-30
Fig. 53 Reamer Sizes

REFACING VALVES AND VALVE SEATS

The intake and exhaust valves have a 43-1/4° to
43-3/4° face angle and a 44-1/4° to 44-3/4° seat angle
(Fig. 54).
CONTACT
Fig. 51 Positioning Valve with Tool C-3973 POINT
4574° - 4574°
(2) Attach Dial Indicator Tool C-3339 to cylinder
head and set i t at right angle of valve stem being
measured (Fig. 52).
INTAKE 1.016-1.524 mm (0.040 - 0.060 in.)

EXHAUST 1.524 - 2.032 mm (0.060 - 0.080 in.)
B - FACE ANGLE (INTAKE & EXHAUST) 4374° - 43 A 3 0
C - SEAT ANGLE (INTAKE & EXHAUST) 4474° - 447*°

D - CONTACT SURFACE
J9209-91
J9309-95
Fig. 52 Measuring Valve Guide Wear

Fig. 54 Valve Face and Seat Angles
(3) Move valve to and from the indicator. The total WALWES
dial indicator reading should not exceed 0.432 mm
(0.017 inch). Ream the guides for valves with over
size stems i f dial indicator reading is excessive or i f
(0.047 inch) margin should be discarded.
the stems are scuffed or scored.
(4) Service valves with oversize stems are avail WALWE SEATS
able (Fig. 53).
(5) Slowly turn reamer by hand and clean guide CAUTION: DO NOT un-shroud valves during valve
thoroughly before installing new valve. Ream the seat refacing (Fig. 56).
valve guides from standard to 0.381 mm (0.015
inch). Use a 2 step procedure so the valve (1) When refacing valve seats, it is important that
guides are reamed true in relation to the valve the correct size valve guide pilot be used for reseat
seat: ing stones. A true and complete surface must be
• Step 1—Ream to 0.0763 mm (0.003 inch). obtained.
9 - 82 S.2L ENGINE BR
DISASSEMBLY AND A S S E M B L Y (Continued)

the spring to be tested is 1-5/16 inch. Turn table of
Universals Valve Spring Tester Tool until surface is
INTAKE EXHAUST
VALVE VALVE
in line with the 1-5/16 inch mark on the threaded
FACE stud. Be sure the zero mark is to the front (Fig. 57).
Place spring over stud on the table and lift compress
ing lever to set tone device. Pull on torque wrench
until ping is heard. Take reading on torque wrench
* STEM - at this instant. Multiply this reading by 2. This will
give the spring load at test length. Fractional mea
surements are indicated on the table for finer adjust
ments. Refer to specifications to obtain specified
VALVE SPRING
RETAINER LOCK
height and allowable tensions. Discard the springs
GROOVE that do not meet specifications.
TORQUE
J9209-127
WRENCH
Fig. 55 Intake and Exhaust Waives
VALVE SPRING
TESTER
9509-79
Fig. 57 Testing Valve Spring for Compressed

Length
OIL P U i P
Fig. 56 Refacing Valve Seats DISASSEMBLE

(1) Remove the relief valve as follows:
(2) Measure the concentricity of valve seat using a (a) Remove cotter pin. Drill a 3.175 mm (1/8
dial indicator. Total runout should not exceed 0.051 inch) hole into the relief valve retainer cap and
mm (0.002 Inch) total indicator reading. insert a self-threading sheet metal screw.
(3) Inspect the valve seat with Prussian blue to (b) Clamp screw into a vise and while support
determine where the valve contacts the seat. To do ing oil pump, remove cap by tapping pump body
this, coat valve seat LIGHTLY with Prussian blue using a soft hammer. Discard retainer cap and
then set valve in place. Rotate the valve with light remove spring and relief valve (Fig. 58).
pressure. I f the blue is transferred to the center of (2) Remove oil pump cover (Fig. 59).
valve face, contact is satisfactory. I f the blue is trans (3) Remove pump outer rotor and inner rotor with
ferred to the top edge of valve face, lower valve seat shaft (Fig. 59).
with a 15° stone. I f the blue is transferred to bottom (4) Wash all parts in a suitable solvent and inspect
edge of valve face raise valve seat with a 60° stone. carefully for damage or wear.
intake seats should be 1.016-1.524 mm (0.040-0.060 ASSEMBLE
inch). The width of the exhaust seats should be (1) Install pump rotors and shaft, using new parts
1.524-2.032 mm (0.060-0.080 inch). as required.
(2) Position the oil pump cover onto the pump
VALVE SPRING INSPECTION body. Tighten cover bolts to 11 N-m (95 in. lbs.)
Whenever valves have been removed for inspection, torque.

OIL PUMP ASSEMBLY C L E A H 1 H G AMD I^SPECYICM
CYLINDER HEADS
CLEANING
Clean all surfaces of cylinder block and cylinder
heads.
SPRING COTTER PIN
INSPECTION
RELIEF VALVE
exceeds 0.00075 mm/mm (0.00075 inch/inch) times
RH174
the span length in inches in any direction, either
* RETAINER CAP replace head or lightly machine the head surface.
FOR EXAMPLE: A 305 mm (12 inch) span is
Fig. 58 Oii Pressure Relief Valve
0.102 mm (0.004 inch) out-of-flat. The allowable out-
INNER ROTOR DISTRIBUTOR DRIVESHAFT of-flat is 305 x 0.00075 (12 x 0.00075) equals 0.23
AND SHAFT BODY (REFERENCE) mm (0.009 inch). This amount of out-of-flat is accept
able.
OUTER ROTOR The cylinder head surface finish should be
COTTER PIN
1.78-3.00 microns (70-125 micro inches).
COVER Inspect push rods. Replace worn or bent rods.
PISTON AND CONNECTING ROD ASSEMBLY

RETAINER
BOLT CAP INSPECTION
SPRING Check the crankshaft connecting rod journal for
LARGE CHAMFERED
EDGE RY10B excessive wear, taper and scoring.
Check the cylinder block bore for out-of-round,
Fig. 59 Oil Pump taper, scoring and scuffing.
(3) Install the relief valve and spring. Insert the Check the pistons for taper and elliptical shape
cotter pin. before they are fitted into the cylinder bore (Fig. 60).
(4) Tap on a new retainer cap.
(5) Prime oil pump before installation by filling CRANKSHAFT INSPECTION OF JOURNALS
rotor cavity with engine oil. The crankshaft connecting rod and main journals
should be checked for excessive wear, taper and scor
CYLINDER BLOCK ing. The maximum taper or out-of-round on any
crankshaft journal is 0.025 mm (0.001 inch).
DISASSEMBLE Journal grinding should not exceed 0.305 mm
Engine assembly removed from vehicle: (0.012 inch) under the standard journal diameter. DO
(1) Remove the cylinder head. NOT grind thrust faces of No.3 main bearing. DO
(2) Remove the oil pan. NOT nick crank pin or bearing fillets. After grinding,
(3) Remove the piston and connecting rod assem remove rough edges from crankshaft oil holes and
blies. clean out all oil passages.
ASSEMBLE CAUTION: After any journal grind, it is important

(1) Install the piston and connecting rod assembly. that the final paper or cloth polish be in the same
(2) Install the oil pan. direction as the engine rotates.
(3) Install the cylinder head.
OIL PAN
CLEANING
9 - 84 5.2L ENGINE — _ _ _ _ _ BR
C L E A N I N G AND I N S P E C T I O N (Continued)
PISTON PIN BORE DIAMETER
8020cd6e

inch) or less or i f the diameter is 62.7 mm (2.469
inches) or less, replace outer rotor (Fig. 62).
A
PISTON A D!A = PISTON DIAMETER BORE DIAMETER
SIZE MIN, mm (IN.) MAX. min (IN.) MIN. mm (IN.) MAX. mm (IN.)
A 99.280 (3.9087) 99.294 (3.9092) 99.306 (3.9097) 99.319(3.9102)
B 99.294 (3.9092) 99.306 (3.9097) 99.319(3.9102) 99.332 (3.9107)
C 99.306 (3.9097) 99.319(3.9102) 99.332 (3.9107) 99.344(3.9112)
D 99.319(3.9102) 99.332 (3.9107) 99.344 (3.9112) 99.357 (3.9117)
E 99.332 (3.9107) 99.344 (3.9112) 99.357 (3.9117) 99.370(3.9122)
J9509-80

Trim or remove excess sealant film in the rear
the sealant inside the rear main cap slots.
If present, trim excess sealant from inside the
engine.
Clean oil pan in solvent and wipe dry with a clean Fig. 62 Measuring Outer Rotor Thickness
cloth. If inner rotor measures 20.9 mm (0.825 inch) or
Clean oil screen and pipe thoroughly in clean sol less, replace inner rotor and shaft assembly (Fig. 63).
vent. Inspect condition of screen.
INSPECTION
Inspect oil pan mounting flange for bends or distor
tion. Straighten flange, i f necessary.
OIL P U i P
INSPECTION
or grooved.
(Fig. 61). I f a 0.038 mm (0.0015 inch) feeler gauge
can be inserted between cover and straightedge, Fig. 63 Measuring Inner Rotor Thickness
pump assembly should be replaced.
Measure thickness and diameter of OUTER rotor. Slide outer rotor into pump body. Press rotor to the
If outer rotor thickness measures 20.9 mm (0.825 side with your fingers and measure clearance
between rotor and pump body (Fig. 64). I f clearance
is 0.356 mm (0.014 inch) or more, replace oil pump
assembly.
8020cd71
8020cd6f
Fig. 66 Measuring Clearance Over Rotors

Fig. 64 Measuring Outer Rotor Clearance in
Housing
Install inner rotor and shaft into pump body. I f
mm (0.008 inch) or more, replace shaft and both
rotors (Fig. 65).
RN98
Fig. 67 Proper Installation of Retainer Cap

CYLINDER BLOCK
CLEANING
hole plugs for evidence of leaking.
Fig. 65 Measuring Clearance Between Rotors INSPECTION

Examine block for cracks or fractures.
The cylinder walls should be checked for out-of-
round and taper with Cylinder Bore Indicator Tool
(0.004 inch) or more can be inserted between rotors
C-119. The cylinder block should be bored and honed
with new pistons and rings fitted if:
66).
Inspect oil pressure relief valve plunger for scoring
(0.005 in.) out-of-round.
and free operation in its bore. Small marks may be
removed with 400-grit wet or dry sandpaper.
0.254 mm (0.010 in.).
The relief valve spring has a free length of approx
imately 49.5 mm (1.95 inches). The spring should
Boring and honing operation should be closely coor
test between 19.5 and 20.5 pounds when compressed
dinated with the fitting of pistons and rings, so that
to 34 mm (1-11/32 inches). Replace spring that fails
specified clearances can be maintained.
to meet these specifications (Fig. 67).
I f oil pressure was low and pump is within specifi OIL LINE PLUi
cations, inspect for worn engine bearings or other The oil line plug is located in the vertical passage
reasons for oil pressure loss. at the rear of the block between the oil-to-filter and
I - 86 5.2L ENGINE
m
oil-from-filter passages (Fig. 68). Improper installa RIGHT OIL GALLERY
tion or plug missing could cause erratic, low, or no oil
pressure.
The oil plug must come out the bottom. Use flat
dowel, down the oil pressure sending unit hole from CYLINDER
the top, to remove oil plug. BLOCK
(1) Remove oil pressure sending unit from back of

block.
(2) Insert a 3.175 mm (1/8 in.) finish wire, or
equivalent, into passage.
PLUG
7-11/16 in.) from machined surface of block (Fig. 68). O I L F R O M FILTER
~ TO SYSTEM
I f plug is too high, use a suitable flat dowel to posi
tion properly.
(4) I f plug is too low, remove oil pan and No. 4
OIL T O FILTER
main bearing cap. Use suitable flat dowel to position
properly. Coat outside diameter of plug with Mopar
Stud and Bearing Mount Adhesive, or equivalent.
Plug should be 54.0 to 57.7 mm (2-1/8 to 2-5/16 in.)
from bottom of the block.
CRANKSHAFT F R O M OIL PUMP J9209-147
Fig. 68 Oil Line Plug

SPECIFICATIONS
5.2L ENGINE SPECIFICATIONS

Camshaft
Bearing Diameter End Play 0.051-0.178 mm
No. 1 . . . . . . . . . 50.800-50.825 mm (0.002-0.007 in)
(2.000-2.001 in) Max. Allowable 0.254 mm
No. 2 50.394-50.419 mm (0.010 in)
(1.984-1.985 in) Main Bearing Journals
No. 3 . . . . . . . . . . . . . . 50.013-50.038 mm Diameter 63.487-63.513 mm
(1.969-1.970 in) (2.4995-2.5005 in)
No. 4 49.606-49.632 mm Out-of-Round (Max.) 0.0254 mm
(1.953-1.954 in) (0.001 in)
No. 5 . . . . . 39.688-39.713 mm Taper (Max.) . . . . . . . . . . . . . . . . . . 0.0254 mm
(1.5625-1.5635 in) (0.001 in)
Diametrical Clearance 0.0254-0.0762 mm
(0.001-0.003 in) Cylinder Block
Max. Allowable . 0.127 mm Cylinder Bore
(0.005 in) Diameter . 99.314-99.365 mm
End Play 0.051-0.254 mm (3.910-3.912 in)
(0.002-0.010 in) Out-of-Round (Max.) 0.127 mm
Bearing Journal Diameter (0.005 in)
No. 1 50.749-50.775 mm Taper (Max.) 0.254 mm
(1.998-1.999 in) (0.010 in)
No. 2 50.343-50.368 mm Oversize (Max.) 1.016 mm
(1.982-1.983 in) (0.040 in)
No. 3 . 49.962-49.987 mm Distributor Lower Drive Shaft
(1.967-1.968 in) Bushing (Press Fit in Block) 0.0127-0.3556 mm
No. 4 49.555-49.581 mm (0.0005-0.0140 in)
(1.951-1.952 in) Shaft-to-Bushing Clearance . 0.0178-0.0686 mm
No. 5 39.637-39.662 mm (0.0007-0.0027 in)
(1.5605-1.5615 in) Tappet Bore Diameter . . . . . . . . . . . . . 22.99-23.01 mm
(0.9051-0.9059 in)
Connecting Rods
Bearing Clearance.... 0.013-0.056 mm Cylinder Head
(0.0005-0.0022 in) Compression Pressure 689 kPa
Max. Allowable 0.08 mm (0.003 in) (100 psi)
Piston Pin Bore Diameter 24.966-24.978 mm Gasket Thickness (Compressed) 1.2065 mm
(0.9829-0.9834 in) (0.0475 in)
Side Clearance (Two Rods) . . . . . . . . . 0.152-0.356 mm Valve Seat
(0.006-0.014 in) Angle 44.25° - 44.75°
Total Weight (Less Bearing) 726 grams Runout (Max.) 0.0762 mm
(25.61 oz) (0.003 in)
Width (Finish) - Intake 1.016-1.524 mm
Crankshaft (0.040-0.060 in)
Connect Rod Journal Width (Finish) - Exhaust 1.524-2.032 mm
Diameter 53.950-53.975 mm (0.060-0.080 in)
(2.124-2.125 in)
Out-of-Round (Max.) 0.0254 mm Hydraulic Tappets
(0.001 in) Body Diameter 22.949-22.962 mm
Taper (Max.) 0.0254 mm (0.9035-0.9040 in)
(0.001 in) Clearance in Block 0.0279-0.0610 mm
(0.0011-0.0024 in)
Diametrical Clearance Dry Lash . . . . . . . ............ 1.524-5.334 mm
No. 1 0.013-0.038 mm (0.060-0.210 in)
(0.0005-0.0015 in) Push Rod Length 175.64-176.15 mm
Nos. 2, 3, 4 and 5 0.013-0.051 mm (6.915-6.935 in)
(0.005-0.0020 in)
Max. Allowable (Nos. 2, 3, 4 & 5) 0.064 mm
(0.0025 in)
J9509-66
i - 88 5.2L ENGINE > BR

Clearance Over Rotors (Max.) 0.1016 mm Clearance
(0.004 in) In Piston 0.00635-0.01905 mm
Cover Out-of-Flat (Max.) 0.0381 mm (0.00025-0.00075 in)
(0.0015 in) In Rod (Interference) . . 0.0178-0.0356 mm
Inner Rotor Thickness (Min.) . . . . . . 20.955 mm (0.0007-0.0014 in)
(0.825 in) Diameter 24.996-25.001 mm
Outer Rotor (0.9841-0.9843 in)
Clearance (Max.) 0.3556 mm End Play NONE
(0.014 in) Length 75.946-76.454 mm
Diameter (Min.) 62.7126 mm (2.990-3.010 in)
(2.469 in)
Thickness (Min.) 20.955 mm Piston Rings
(0.825 in) Ring Gap
Tip Clearance Between Rotors (Max). . 0.2032 mm Compression Rings 0.254-0.508 mm
(0.008 in) (0.010-0.020 in)
Oil Control (Steel Rails) . 0.254-1.270 mm
Oii Pressure (0.010-0.050 in)
At Curb Idle Speed (Minimum)*. . . . . . 41.4 kPa Ring Side Clearance
(6 psi) Compression Rings 0.038-0.076 mm
At 3000 rpm 207-552 kPa (0.0015-0.0030 in)
(30-80 psi) Oil Ring (Steel Rails) 0.06-0.21 mm
Oil Pressure Switch (0.002-0.008 in)
Actuating Pressure (Min.) . . . . . . . 34.5-48.3 kPa Ring Width
(5-7 psi) Compression Rings 1.971-1.989 mm
(0.0776-0.0783 in)
* CAUTION: If pressure is ZERO at curb idle, Oil Ring (Steel Rails) 3.848-3.975 mm
DO NOT run engine at 3,000 rpm. (0.1515-0.1565 in)
O i l Filter Valves
Bypass Valve Setting 62-103 kPa Face Angle 43.25°-43.75°
(9-15 psi) Head Diameter
Intake 48.666 mm
Pistons (1.916 in)
Clearance at Top of Skirt . . . . . . . . 0.0127-0.0381 mm Exhaust . 41.250 mm
(0.0005-0.0015 in) (1.624 in)
Land Clearance (Diametrical) . . . . . 0.635-1.016 mm Length (Overall)
(0.025-0.040 in) Intake 124.28-125.92 mm
Piston Length . . . . . . . . . . . . . . . . . 86.360 mm (4.893-4.918 in)
(3.40 in) Exhaust 124.64-125.27 mm
Piston Ring Groove Depth (4.907-4.932 in)
Nos. 1 and 2 4.572-4.826 mm Lift (Zero Lash) 10.973 mm
(0.180-0.190 in) (0.432 in)
No. 3 3.810-4.064 mm Stem Diameter . . . . . ....... 7.899-7.925 mm
(0.150-0.160 in) (0.311-0.312 in)
Weight . . . . . . . . . . . . . . . . . . . . . . 592.6-596.6 grams Stem-to-Guide Clearance . 0.0254-0.0762 mm
(20.90-21.04 oz) (0.001-0.003 in)
Max. Allowable (Rocking Method). . 0.4318 mm
(0.017 in)
Guide Bore Diameter (Std) . . . . . . . 7.950-7.976 mm
(0.313-0.314 in)
J9509-67

Free Length (Approx.) . . . . . . . . . . . 49.962 mm Exhaust Valve
' (1.967 In) Closes (ATC) 21°
Spring Tension @ 41.66 mm = 378 N Opens (BBC) 60°
(Valve Closed) (@ 1.64 in = 85 lbs) Duration 264°
(Valve Open) (@ 1.212 in = 2 0 0 lbs) Closes (ABC) 61°
Number of Coils 6.8 Opens (BTC) 10°
Installed Height 41.66 mm Duration 250°
(Spring Seat to Retainer) (1.64 in) Valve Overlap 31 °
Wire Diameter 4 . 5 0 mm
(0.177 in)
J9409-99
CONDITION IDENTIFICATION LOCATION OF IDENTIFICATION
CRANKSHAFT JOURNALS RorM Milled flat on no. 8 crankshaft counterweight.

(UNDERSIZE) M-2-3 etc. (indicating no. 2 and 3 main bearing
0.0254 mm (0.001 in.) journal)
and/or
R-l -4 etc. (indicating no. 1 and 4 connecting rod
journal)
HYDRAULIC TAPPETS Diamond-shaped stamp top pad - front of

(OVERSIZE) engine and flat ground on outside surface of
0.2032 mm (0.008 in.) each O / S tappet bore.

J9309-82
OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS

I - II S.2L ENGINE
Adjusting Strap Bolt 23 N«m (200 in. lbs.) Rear Mount - Support Cushion-to-
Crossmember Nut 47 N T n (35ft.lbs.)
Camshaft Bolt 68 N*m (50 ft. lbs.) Rear Mount - Support Cushion-to-
Camshaft Thrust Plate Bolts 24 N*m (210 in. lbs.] Trans. Support Bracket Nuts 4 7 N * m (35ft.lbs.)
Chain Case Cover Bolts 41 N®m (30 ft. lbs.) Rear Mount - Transmission Support
Connecting Rod Cap Bolts 61 N«m (45 ft. lbs.) Bracket Bolts 102 N T n (75ft.lbs.)
Crankshaft Main Bearing Cap Bolts .... 115 N*m (85 ft. lbs.) Rear Support Plate-to-Transfer
Cylinder Head Bolts Case Bolts 41 N T n (30ft.lbs.)
1 st Step 68 N«m (50ft.lbs.) Rocker Arm Bolts 2 3 N * m (200 in. lbs.]
2nd Step 143 N*m (105 ft. lbs.)
Cylinder Head Cover Bolts 11 N@m (95 in. lbs.) Spark Plugs 41 N*m (30ft.lbs.)
Starter Mounting Bolts (50ft.lbs.)
Exhaust Manifold-to-Cylinder 68 N T n
34 N®m (25 ft. lbs. Throttle Body Bolts (200 in. lbs.]
Torque Converter Drive Plate 23 N T n
68 N«m (50 ft. lbs. Bolts (270 in. lbs.;
Front Mount - Engine Support Transfer Case-to-lnsulator 31 N*m
81 N«m (60 ft. lbs. Mounting Plate Nuts (150 ft. lbs.)
204 N T n
41 N®m (30 ft. lbs. Vibration Damper Retainer
Bolt 183 N T H (135ft.lbs.)
Intake Manifold Bolts Refer to Procedure
in Service Manual. Water Pump-to-Chain Case
Cover Bolt 41 N T n (30ft.lbs.)
Oil Pan Bolts 23 N*m (200 in. lbs.]
Oil Pan Drain Plug 34 N*m (25ft.lbs.)
Oil Pump Attaching Bolts 41 N*m (30ft.lbs.)
Oil Pump Cover Bolts 11 N»m (95 in. lbs.) J9509-140
mm — - — - 5.2L ENGINE 1 - 9.1
SPECIAL TOOLS
5.2L ENGINE
Oil Pressure Gauge C-3292
Valve Guide Sleeve C-3973
Engine Support Fixture C-3487-A
Dial indicator C-3339
Puller C-3688
Adapter 6688
9 • 92 5.2L ENGINE —
mm
Front Oil Seal Installer 6635 Distributor Bushing Driver/Burnisher C-3053
801W423
Cam Bearing Remover/Installer C-3132-A Piston Ring Compressor C-385
Camshaft Holder C-3509 Crankshaft Main Bearing Remover C-3059
8011C9T'CJ
Distributor Bushing Puller C-3052 Cylinder Bore Gauge C-119

5.9L EHG1NE
INDEX
page page
GENERAL INFORMATION FRONT CRANKSHAFT OIL SEAL 112

OIL PUMP P R E S S U R E 93 HYDRAULIC TAPPETS 104
PISTON AND CONNECTING ROD ASSEMBLY . . 93 OIL PAN 109
DESCRIPTION AND OPERATION OIL PUMP 112
ENGINE COMPONENTS 96 PISTON AND CONNECTING ROD ASSEMBLY . 110
ENGINE DESCRIPTION 93 ROCKER ARMS AND PUSH RODS 102
LUBRICATION SYSTEM 94 TIMING CHAIN COVER 105
SERVICE PROCEDURES TIMING CHAIN 106
CRANKSHAFT S E R V I C E 99 VALVE SPRING AND STEM SEAL
FITTING CONNECTING ROD BEARINGS 98 REPLACEMENT-IN VEHICLE 103
FITTING CRANKSHAFT MAIN BEARINGS 98 VALVES AND VALVE SPRINGS 104
FITTING PISTON RINGS 97 VIBRATION DAMPER 104
FITTING PISTONS 97 DISASSEMBLY AND ASSEMBLY
MEASURING TIMING CHAIN S T R E T C H 96 CYLINDER BLOCK 115
VALVE TIMING 96 HYDRAULIC TAPPETS 115
REMOVAL AND INSTALLATION OIL PUMP 117
CAMSHAFT BEARINGS 108 VALVE SERVICE 116
CAMSHAFT 107 CYLINDER BLOCK 120
CRANKSHAFT MAIN BEARINGS 109 CYLINDER HEAD ASSEMBLY 118
CRANKSHAFT REAR OIL S E A L S . . 113 OIL PAN 119
CRANKSHAFT 111 OIL PUMP 119
CYLINDER HEAD COVER 102 PISTON AND CONNECTING ROD ASSEMBLY . 118
CYLINDER HEADS 103 SPECIFICATIONS
ENGINE ASSEMBLY 100 5.9L ENGINE 121
ENGINE C O R E PLUGS 114 SPECIAL TOOLS
ENGINE FRONT MOUNTS 99 5.9L ENGINE 124
ENGINE REAR MOUNT 100
GENERAL INFORMATION All pistons are machined to the same weight,

The MINIMUM oil pump pressure is 41.4 kPa (6 retained by the press interference fit of the piston
CAUTION: If oil pressure is ZERO at curb idle, DO DESCRIPTION AND OPERATION

ENGINE DESCRIPTION
The 5.9 Liter (360 CID) eight-cylinder engine is a
PISTON AND CONNECTING ROD ASSEMBLY V-Type lightweight, single cam, overhead valve
diameter at the pin boss is less than its diameter This engine is designed for unleaded fuel.
across the thrust face. This allows for expansion Engine lubrication system consists of a rotor type
under normal operating conditions. Under operating oil pump and a full flow oil filter.
temperatures, expansion forces the pin bosses away The cylinders are numbered from front to rear; 1,
from each other, causing the piston to assume a more 3, 5, 7 on the left bank and 2, 4, 6, 8 on the right
nearly round shape. bank. The firing order is 1-8-4-3-6-5-7-2 (Fig. 2).
9 - 94 5.9L ENGINE — BR
90° V-8 a w X M 5.9L I XXXX XXXXXXXX

Bore and Stroke 101.6 x 90.9 mm (4.00 x 3.58 in.)
5.9L (360 cu. if
Compression Ratio X = Last Digit of Model Year
448 N<>m (330ft.lbs.) © 3,250 rpm M = Plant - M Mound Road
1-8-4-3-6-5-7-2 S Saltillo
Pressure Feed - Full Flow Fihraticn T Trenton
.......4.7L(5.0^)w/fil^ K Toluca
Cooling System Liquid Cooled - Forced Circulation 5.9L = Engine Displacement
14.7L(15.5 Qts) - T = Usage - T Truck
Cylinder Block Cast Iron XXXX = Month/Day
XXXXXXXX = Serial Code - Last 8 Digits of VIN No.
Cylinder Head............. Cast Iron
Combustion Chambers. ...Wedge-High Swirl Valve Shrouding
J9209-74
Camshaft Nodular Cast Iron
Fig. 3 Engine Identification Number

and pump body, then forced through the outlet to the
block. An oil gallery in the block channels the oil to
the inlet side of the full flow oil filter. After passing
J9409-11
through the filter element, the oil passes from the
center outlet of the filter through an oil gallery that
channels the oil up to the main gallery which
extends the entire length on the right side of the
block. The oil then goes down to the No. 1 main bear
ing, back up to the left side of the block and into the
lery to the upper shell of each main bearing. The
Each connecting rod bearing has half a hole in it, oil
rotates. This oil throw off lubricates the camshaft
ton pins.
J908D-49 The hydraulic valve tappets receive oil directly
Fig. 2 Firing Order receive oil from the main bearing galleries. The front
The engine serial number is stamped into a camshaft bearing journal passes oil through the cam
machined pad located on the left, front corner of the shaft sprocket to the timing chain. Oil drains back to
cylinder block. When component part replacement is the oil pan under the number one main bearing cap.
necessary, use the engine type and serial number for The oil supply for the rocker arms and bridged
reference (Fig. 3). pivot assemblies is provided by the hydraulic valve
tappets which pass oil through hollow push rods to a
LUBRICATION SYSTEM hole in the corresponding rocker arm. Oil from the
A gear—type positive displacement pump is rocker arm lubricates the valve train components.
mounted at the underside of the rear main bearing The oil then passes down through the push rod guide
cap. The pump draws oil through the screen and holes, and the oil drain back passages in the cylinder
inlet tube from the sump at the rear of the oil pan. head past the valve tappet area, and returns to the
The oil is driven between the drive and idler gears oil pan.
BOLT
OIL D E F L E C T O R R O C K E R ARM
TAB PIVOT R O C K E R ARM
ROCKER
OIL SUPPLY ARM
FROM HOLLOW TO MAIN
PUSH ROD BEARINGS
DRIP OILING HOLLOW
FOR VALVE TIP PUSH ROD
CYLINDER HEAD
BOSS TAPPET
OIL SUPPLY VIA
HOLLOW PUSH ROD
SUPPLY IS FROM OIL
G A L L E R Y M E T E R E D THROUGH
HYDRAULIC TAPPET
OIL PASSAGE FOR OIL

P R E S S U R E INDICATOR LIGHT
RIGHT OIL G A L L E R Y
PASSAGE
TO CAMSHAFT
REAR BEARING

PLUG TO S Y S T E M ROD BEARINGS
CRANKSHAFT

ENGINE COMPONENTS (4) Rotate the crankshaft clockwise (normal run
ning direction) until the valve has lifted 0.863 mm
CYLINDER HEADS (0.034 inch). The timing of the crankshaft should
The alloy cast iron cylinder heads (Fig. 5) are held now read from 10° before top dead center to 2° after
in place by 10 bolts. The spark plugs are located in top dead center. Remove spacer.
the peak of the wedge between the valves.
The 5.9L cylinder head is identified by the foundry CAUTION: DO NOT turn crankshaft any further
mark CF. clockwise as valve spring might bottom and result
in serious damage.
EXHAUST SPARK EXHAUST SPARK EXHAUST
VALVE PLUGS VALVES PLUGS VALVE
If reading is not within specified limits:
• Check sprocket index marks.
• Inspect timing chain for wear.
• Check accuracy of DC mark on timing indicator.
MEASURING TIMING CHAIN STiETCH

NOTE: To access timing chain Refer to Timing
Chain Cover in Removal and Installation Section.

INTAKE INTAKE (2) Place a torque wrench and socket over cam
VALVES VALVES J9309-37 shaft sprocket attaching bolt. Apply torque in the
Fig. 5 Cylinder Head Assembly N-m (30 ft. lbs.) torque with cylinder head installed
PISTONS or 20 N-m (15 ft. lbs.) torque with cylinder head
The pistons are elliptically turned so that the removed. With a torque applied to the camshaft
diameter at the pin boss is less than its diameter sprocket bolt, crankshaft should not be permitted to
across the thrust face. This allows for expansion move. I t may be necessary to block the crankshaft to
under normal operating conditions. Under operating prevent rotation.
temperatures, expansion forces the pin bosses away (3) Hold a scale with dimensional reading even
from each other, causing the piston to assume a more with the edge of a chain link. With cylinder heads
nearly round shape. installed, apply 14 N-m (30 ft. lbs.) torque in the
All pistons are machined to the same weight, reverse direction. With the cylinder heads removed,
regardless of size, to maintain piston balance. apply 20 N-m (15 ft. lbs.) torque in the reverse direc
The piston pin rotates in the piston only and is tion. Note the amount of chain movement (Fig. 6).
WALWES AND WALWE SPRINGS

The valves are arranged in-line and inclined 18°.
The rocker pivot support and the valve guides are
cast integral with the heads.
SERVICE PROCEDURES
VALVE TIMING
(1) Turn crankshaft until the No.6 exhaust valve is Fig. 6 Measuring Timing Chain Wear and Stretch
closing and No.6 intake valve is opening.
(2) Insert a 6.350 mm (1/4 inch) spacer between (4) Install a new timing chain, i f its movement
rocker arm pad and stem tip of No.l intake valve. exceeds 3.175 mm (1/8 inch).
Allow spring load to bleed tappet down giving in (5) I f chain is not satisfactory, remove camshaft
effect a solid tappet. sprocket attaching bolt and remove timing chain with
(3) Install a dial indicator so plunger contacts crankshaft and camshaft sprockets.
valve spring retainer as nearly perpendicular as pos (6) Place both camshaft sprocket and crankshaft
sible. Zero the indicator. sprocket on the bench with timing marks on exact
BR 5.9L ENGINE I -17
imaginary center line through both camshaft and PISTON PIN BORE DIAMETER
crankshaft bores.
(8) Turn crankshaft and camshaft to line up with
shaft sprocket.
A
PISTON A DIA = PISTON DIAMETER BORE DIAMETER
A
B 101.580 (3.9992) 101.592 (3.9997) 101.605 (4.0002) 101.618(4.0007)
Fig. 7 Alignment of Timing Marks C 101.592 (3.9997) 101.605 (4.0002) 101.618(4.0007) 101.630 (4.0012)
D 101.605 (4.0002) 101.618(4.0007) 101.630 (4.0012) 101.643 (4.0017)
(11) Install the camshaft bolt. Tighten the bolt to
E
J9509-79
(12) Check camshaft end play. The end play should Fig. 8 Piston Measurements
thrust plate and up to 0.254 mm (0.010 inch) with a (a) Measure piston ring gap 2 inches from bot
used thrust plate. I f not within these limits install a tom of cylinder bore. An inverted piston can be
new thrust plate. used to push the rings down to ensure positioning
rings squarely in the cylinder bore before measur
FITTING PISTONS ing.
Piston and cylinder wall must be clean and dry. (b) Insert feeler gauge in the gap. The top com
Specified clearance between the piston and the cylin pression ring gap should be between 0.254-0.508
der wall is 0.013-0.038 mm (0.0005-0.0015 inch) at mm (0.010-0.020 inch). The second compression
21°C (70°F). ring gap should be between 0.508-0.762 mm (0.020-
Piston diameter should be measured at the top of 0.030 inch). The oil ring gap should be 0.254-1.270
skirt, 90° to piston pin axis. Cylinder bores should be mm (0.010-0.050 inch).
measured halfway down the cylinder bore and trans (c) Rings with insufficient end gap may be prop
verse to the engine crankshaft center line. erly filed to - the correct dimension. Rings with
Pistons and cylinder bores should be measured at excess gaps should not be used.
normal room temperature, 21°C (70°F). (2) Install rings and confirm ring side clearance:
Check the pistons for taper and elliptical shape (a) Install oil rings being careful not to nick or
before they are fitted into the cylinder bore (Fig. 8). scratch the piston. Install the oil control rings according
to instructions in the package. It is not necessary to use
FITTING PISTON RINGS a tool to install the upper and lower rails. Insert oil rail
( 1 ) Measurement of end gaps: spacer first, then side rails.
(b) Install the second compression rings using Instal
lation Tool C-4184. The compression rings must be
installed with the identification mark face up (toward
top of piston) and chamfer facing down. An identification
I -18 5.9L ENGINE BR
mark on the ring is a drill point, a stamped letter "0", OIL RING
an oval depression or the word TOP (Fig. 9) (Fig. 11). SPACER GAP
(e) Using a ring installer, install the top com
pression ring with the chamfer facing up (Fig. 10)
(Fig. 11). An identification mark on the ring is a
drill point, a stamped letter "0", an oval depression SECOND
or the word TOP facing up. TOP COMPRESSION
COMPRESSION RING GAP
(d) Measure side clearance between piston ring and OIL RING RAIL
RING GAP
ring land. Clearance should be 0.074-0.097 mm (0.0029- GAP (TOP)
0.0038 inch) for the compression rings. The steel rail oil
ring should be free in groove, but should not exceed
0.246 mm (0.0097 inch) side clearance.
OIL RING RAIL
SECOND COMPRESSION RING CHAMFER GAP (BOTTOM) J9309-80
(BLACK CAST IRON) Fig. 12 Proper Ring Installation
FITTING CONNECTING i O i BEARINGS
The bearing caps are not interchangeable and
assembly.
TWO Each bearing cap has a small V-groove across the
DOTS J9009-46 parting face. When installing the lower bearing shell,
make certain that the V-groove in the shell is in line
Fig. 9 Second Compression Ring identification (Typical)
with the V-groove in the cap. This provides lubrica
TOP COMPRESSION RING tion of the cylinder wall i n the opposite bank.
(GRAY IN COLOR)
tangs are i n the machined grooves in the rods and
CHAMFER
caps.
journals should be held to 0.025 mm ( 0 . 0 0 1 inch).
Bearings are available i n 0.025 mm ( 0 . 0 0 1 inch),
0 . 0 5 1 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254
mm (0.010 inch) and 0.305 mm (0.012 inch) under
size. Install the bearings in pairs. DO NOT use a
new bearing half with an old bearing half. DO
J9009-48
Fig. 10 Top Compression Ring Identification (Typical) NOT file the rods or bearing caps.
CHAMFER TOP COMPRESSION FITTING CRANKSHAFT MAIN BEARINGS

RING
changeable. Lower main bearing halves of No.2 and 4
SECOND Upper and lower No.3 bearing halves are flanged
COMPRESSION to carry the crankshaft thrust loads. They are NOT
RING
interchangeable with any other bearing halves i n the
engine (Fig. 13). Bearing shells are available in stan
i CHAMFER dard and the following undersizes: 0.25 mm ( 0 . 0 0 1
•PISTON J9409-37
Fig. 11 Compression Ring Chamfer Location (Typical) inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch),
0.254 mm (0.010 inch) and 0.305 mm (0.012 inch).
Never install an undersize bearing that will reduce
clearance below specifications.
BR . . 5.9L ENGINE 9 - 99
(0.012 inch) under the standard journal diameter. DO
NOT grind thrust faces of No.3 main bearing. DO
NOT nick crank pin or bearing fillets. After grinding,
clean out all oil passages.

direction as the engine rotates.
Fig. 13 Main Bearing Identification ENGINE FiONT MOUNTS

CRANKSHAFT SERVICE REMOVAL
A crankshaft which has undersize journals will be (1) Disconnect the negative cable from the battery.
stamped with 1/4 inch letters on the milled flat on (2) Position fan to assure clearance for radiator top
the No.3 crankshaft counterweight (Fig. 14). tank and hose.
FOR EXAMPLE: R2 stamped on the No.3 crank
shaft counterweight indicates that the No.2 rod jour CAUTION: DO NOT lift the engine by the intake
nal is 0.025 mm (0.001 in) undersize. M4 indicates manifold.
that the No.4 main journal Is 0.025 mm (0.001 in)
undersize. R3 M2 indicates that the No.3 rod journal (3) Install engine support/lifting fixture.
and the No.2 main journal are 0.025 mm (0.001 in) (4) Raise vehicle on hoist.
undersize. (5) Lift the engine SLIGHTLY and remove the
thru-bolt and nut (Fig. 15).
(6) Remove engine support bracket/cushion bolts
Undersize Journal Identification Stamp (Fig. 15). Remove the support bracket/cushion and
0.025 m m ( 0 . 0 0 1 inch) (Rod) R1-R2-R3 or R4 heat shields.
0.025 m m (0.001 inch) (Main) M 1 - M 2 - M 3 - M 4 or M 5
Fig. 14 Location of Crankshaft Identification

When a crankshaft is replaced, all main and con RESTRICTION PADS
necting rod bearings should be replaced with new J9409-144

is not required when a crankshaft and bearings are Fig. 15 Engine Front Mounts
replaced. INSTALLATION
(1) With engine raised SLIGHTLY, position the
INSPECTION OF JOURNALS engine support bracket/cushion and heat shields to
The crankshaft connecting rod and main journals the block. Install new bolts and tighten to 81 N-m (60
should be checked for excessive wear, taper and scor- ft. lbs.) torque.
S - 100 5.9L ENGINE BR
(2) Install the thru-bolt into the engine support (3) Using the transmission jack, lower the trans
bracket/cushion. mission and support cushion onto the crossmember
(3) Lower engine with support/lifting fixture while (Fig. 17).
guiding the engine bracket/cushion and thru-bolt into (4) Install the support cushion bolts and tighten to
support cushion brackets (Fig. 16). 47 N-m (35 ft. lbs.) torque.
(5) Remove the transmission jack.
ENGINE ASSEMBLY
REMOVAL
ENGINE
SUPPORT
BRACKET/ System for the proper procedure).
CUSHION (3) Remove the upper crossmember and top core
support.
equipped (refer to Group 24, Heating and Air Condi
tioning for service procedures).
(6) Remove the serpentine belt (refer to Group 7,
Cooling System).
(7) Remove the A/C compressor with the lines
SUPPORT
CUSHION
(8) I f equipped, remove the condenser.
BRACKET (9) Remove the washer bottle.
J9409-54 (10) Disconnect the top radiator hose.
(11) Remove the fan.
Fig. 16 Positioning Engine Front Mounts (12) Remove the fan shroud.
(4) Install thru-bolt nuts and tighten the nuts to (13) Disconnect the lower radiator hose.
102 N-m (75 ft. lbs.) torque. (14) Remove radiator (refer to Group 7, Cooling
(5) Lower the vehicle. System).
(6) Remove lifting fixture. (15) Remove the generator with the wire connec
tions (refer to Group 8B, Battery/Starter/Generator
ENGINE REAR MOUNT Service).
REMOVAL (17) Disconnect the throttle linkage.
(1) Raise the vehicle on a hoist. (18) Remove throttle body.
(2) Position a transmission jack in place. (19) Remove the intake manifold (refer to Group
(3) Remove support cushion stud nuts (Fig. 17). 11, Exhaust System and Intake Manifold).
(4) Raise rear of transmission and engine (20) Remove the distributor cap and wiring.
SLIGHTLY. (21) Disconnect the heater hoses.
(5) Remove the bolts holding the support cushion (22) Disconnect the power steering hoses, i f
to the transmission support bracket. Remove the sup equipped.
port cushion. (23) Disconnect the transmission cooler lines.
(6) I f necessary, remove the bolts holding the (24) Perform the Fuel System Pressure Release
transmission support bracket to the transmission. procedure (refer to Group 14, Fuel System). Discon
nect the fuel lines.
INSTALLATION (25) On Manual Transmission vehicles, remove the
(1) I f removed, position the transmission support shift lever (refer to Group 21, Transmissions).
bracket to the transmission. Install new attaching (26) Raise and support the vehicle on a hoist.
bolts and tighten to 102 N-m (75 ft. lbs.) torque. (27) Remove the drain plug and drain the engine
(2) Position support cushion to transmission sup oil.
port bracket. Install stud nuts and tighten to 47 N-m (28) Remove engine front mount thru-bolt nuts.
(35 ft. lbs.) torque. (29) Remove the transmission cooler line brackets
from oil pan.
(30) Disconnect exhaust pipe at manifold.
5.9L ENGINE 9 - 101
REHOWAL ANP I N S T A L L A T I O N fContinued)
Fig. 17 Engine Rear S i / ; wt Cushion Assemblies

(31) Disconnect the starter wires. Remove starter (5) Install rear transmission support.
motor (refer to Group 8 B , Battery/Starter/Generator (6) Install the prop shaft (refer to Group 16, Pro
Service). peller Shaft).
(32) Remove the dust shield and transmission (7) Install the dust shield and transmission cover.
cover. (8) Install the starter and connect the starter
(33) Refer to group 21, Transmissions for trans wires (refer to Group 8B, Battery/Starter/Generator
mission removal. Service).
(34) Remove the prop shaft (refer to Group 16, (9) Install exhaust pipe to manifold.
Propeller Shaft). (10) Install the transmission cooler line brackets
(35) Lower the vehicle. from oil pan.
(36) Install a jack stand under the automatic (11) Install engine front mount thru-bolt nuts.
transmission. Tighten the nuts.
CAUTION; DO NOT lift the engine by the intake (25 ft. lbs.) torque.
manifold. (13) Lower the vehicle.
(14) Remove engine lifting fixture,
(37) Install an engine lifting fixture. (15) On Manual Transmission vehicles, install the
(38) Remove engine from vehicle and install shift lever (refer to Group 21, Transmissions).
engine assembly on a repair stand. (16) Connect the fuel lines.
INSTALLATION
tion in the engine compartment. Position the thru-
(20) Install the distributor cap and wiring.
bolt into the support cushion brackets.
(21) Install the intake manifold (refer to Group 11,
Exhaust System and Intake Manifold).
(4) Refer to Group, 21 Transmissions for transmis
sion installation
(22) Using a new gasket, install throttle body. INSTALLATION

Tighten the throttle body bolts to 23 N-m (200 in. (1) Clean cylinder head cover gasket surface.
lbs.) torque. (2) Clean head rail, i f necessary.
(23) Connect the throttle linkage. (3) Inspect cover for distortion and straighten, i f
(24) Install the air cleaner box. necessary.
(25) Install the generator and wire connections (4) Check the gasket for use i n head cover instal
(refer to Group 8B, Battery/Starter/Generator Ser lation. I f damaged, use a new gasket.
vice). (5) Position the cylinder head cover onto the gas
(26) Install radiator (refer to Group 7, Cooling Sys ket. Tighten the bolts to 11 N-m (95 in. lbs.) torque.
tem). (6) Install closed crankcase ventilation system and
(27) Connect the lower radiator hose. evaporation control system.
(28) Install the fan shroud. (7) Connect the negative cable to the battery.
(29) Install the fan.
(30) Connect the top radiator hose. R0CIER ARiS AND PUSH RODS
(31) Install the washer bottle.
(32) I f equipped, install the condenser. REMOVAL
(33) Install the A/C compressor with the lines (1) Disconnect spark plug wires by pulling on the
attached. boot straight out in line with plug.
(34) Install the serpentine belt (refer to Group 7, (2) Remove cylinder head cover and gasket.
Cooling System). (3) Remove the rocker arm bolts and pivots (Fig.
(35) Evacuate and charge the air conditioning sys 19). Place them on a bench in the same order as
tem, i f equipped (refer to Group 24, Heating and Air removed.
Conditioning for service procedures). (4) Remove the push rods and place them on a
(36) Install the transmission oil cooler. bench in the same order as removed.
(37) Install the upper crossmember and top core ROCKER CYLINDER
support.
(38) Add coolant to the cooling system (refer to
Group 7, Cooling System for the proper procedure).
(39) Install the battery
(40) Warm engine and adjust.
CYLINDER HEAD COWER

A steel backed silicon gasket is used with the cyl
J9209-65
inder head cover (Fig. 18). This gasket can be used
again. Fig. 19 Rocker Arms
CYLINDER HEAD INSTALLATION
COVER GASKET V
(1) Rotate the crankshaft until the "V8" mark lines
cover. This mark is located 147° ATDC from the No.l
firing position.
(2) Install the push rods in the same order as
removed.
(3) Install rocker arm and pivot assemblies in the
same order as removed. Tighten the rocker arm bolts
J9209-105 to 28 N-m (21 ft. lbs.) torque.
Fig. 18 Cylinder Head Cover Gasket CAUTION: DO NOT rotate or crank the engine dur
REMOVAL ing or immediately after rocker arm installation.
Allow the hydraulic roller tappets adequate time to
bleed down (about 5 minutes).
(2) Disconnect closed ventilation system and evap
oration control system from cylinder head cover. (4) Install cylinder head cover.
(3) Remove cylinder head cover and gasket. The
(5) Connect spark plug wires.
gasket may be used again.
5.9L ENGINE 9 - 103
mm
i E i i M L l^m I I S T 1 L L A K O I (Continued)
VALVE SPRING AND STEIVI SEAL REPLACEMENT- (13) Disconnect heater hoses and bypass hose.
IN VEHICLE (14) Remove cylinder head covers and gaskets.
(1) Set engine basic timing to Top Dead Center (15) Remove intake manifold and throttle body as
(TDC). an assembly. Discard the flange side gaskets and the
(2) Remove the air cleaner. front and rear cross-over gaskets.
(3) Remove cylinder head covers and spark plugs. (16) Remove exhaust manifolds.
(4) Remove coil wire from distributor and secure to (17) Remove rocker arm assemblies and push rods.
good ground to prevent engine from starting. Identify to ensure installation in original locations.
(5) Using suitable socket and flex handle at crank (18) Remove the head bolts from each cylinder
shaft retaining bolt, turn engine so the No.l piston is head and remove cylinder heads. Discard the cylin
at TDC on the compression stroke. der head gasket.
. (6) Remove rocker arms. (19) Remove spark plugs.
(7) With air hose attached to an adapter installed
INSTALLATION
in N o . l spark plug hole, apply 620-689 kPa (90-100
(1) Position the new cylinder head gaskets onto
psi) air pressure.
the cylinder block.
(8) Using Valve Spring Compressor Tool
(2) Position the cylinder heads onto head gaskets
MD-998772A with adaptor 6633, compress valve
and cylinder block.
spring and remove retainer valve locks and valve
(3) Starting at top center, tighten all cylinder head
spring.
bolts, i n sequence, to 68 N-m (50 ft. lbs.) torque (Fig.
(9) Install seals on the exhaust valve stem and
20). Repeat procedure, tighten all cylinder head bolts
position down against valve guides.
to 143 N-m (105 ft. lbs.) torque. Repeat procedure to
(10) The intake valve stem seals should be pushed
confirm that all bolts are at 143 N-m (105 ft. lbs.)
firmly and squarely over the valve guide using the
torque.
valve stem as a guide. DO NOT force seal against top
of guide. When installing the valve retainer locks,
compress the spring only enough to install the locks.
(11) Follow the same procedure on the remaining 7
cylinders using the firing sequence 1-8-4-3-6-5-7-2.
Make sure piston in cylinder is at TDC on the valve
spring that is being removed.
hole.
(14) Install covers and coil wire to distributor.
CYLINDER HEADS
REMOVAL
(1) Disconnect the negative cable from the battery. Fig. 20 Cylinder Head Bolt Tightening Sequence
CAUTION: When tightening the rocker arm bolts,
make sure the piston in that cylinder is NOT at
TDC. Contact between the valves and piston could
occur.
(4) Remove closed crankcase ventilation system.
(5) Disconnect the evaporation control system. (4) Install push rods and rocker arm assemblies i n
(6) Remove the air cleaner. their original position. Tighten the bolts to 28 N-m
(7) Disconnect the fuel lines. (21 ft. lbs.) torque.
(8) Disconnect accelerator linkage and i f so (5) Install the intake manifold and throttle body
equipped, the speed control and transmission kick- assembly (refer to Group 11, Exhaust System and
down cables. Intake Manifold).
(9) Remove the return spring. (6) Install exhaust manifolds. Tighten the bolts
(10) Remove distributor cap and wires. and nuts to 34 N-m (25 ft. lbs.) torque.
(11) Disconnect the coil wires.
(12) Disconnect heat indicator sending unit wire.
I - 104 5.91 ENGINE
mm
(7) Adjust spark plugs to specifications (refer to cylinder head to the bottom surface of spring
Group 8D, Ignition System). Install the plugs and retainer. I f spacers are installed, measure from the
tighten to 41 N-m (30 ft. lbs.) torque. top of spacer. I f height is greater than 42.86 mm
(8) Install coil wires. (1-11/16 inches), install a 1.587 mm (1/16 inch)
(9) Connect heat indicator sending unit wire. spacer in head counterbore. This should bring spring
(10) Connect the heater hoses and bypass hose. height back to normal 41.27 to 42.86 mm (1-5/8 to
(11) Install distributor cap and wires. 1-11/16 inch).
(12) Hook up the return spring.
(13) Connect the accelerator linkage and i f so HYDRAULIC TAPPETS
equipped, the speed control and transmission kick-
down cables. REMOVAL
(14) Install the fuel lines. (1) Remove the air cleaner.
(15) Install the generator and drive belt. Tighten (2) Remove cylinder head cover.
generator mounting bolt to 41 N-m (30 ft. lbs.) (3) Remove rocker assembly and push rods. Iden
torque. Tighten the adjusting strap bolt to 23 N-m tify push rods to ensure installation i n original loca
(200 in. lbs.) torque. Refer to Group 7, Cooling Sys tion.
tem for adjusting the belt tension. (4) Remove intake manifold.
(16) Install the intake manifold-to-generator (5) Remove yoke retainer and aligning yokes.
bracket support rod. Tighten the bolts. (6) Slide Hydraulic Tappet Remover/Installer tool
(17) Place the cylinder head cover gaskets in posi through opening in cylinder head and seat tool firmly
tion and install cylinder head covers. Tighten the in the head of tappet.
bolts to 11 N-m (95 in. lbs.) torque. (7) Pull tappet out of bore with a twisting motion.
(18) Install closed crankcase ventilation system. If all tappets are to be removed, identify tappets to
(19) Connect the evaporation control system. ensure installation i n original location.
(20) Install the air cleaner. (8) I f the tappet or bore in cylinder block is scored,
(21) Install the heat shields. Tighten the bolts to scuffed, or shows signs of sticking, ream the bore to
41 N-m (30 ft. lbs.) torque. next oversize. Replace with oversize tappet.
System for proper procedure). INSTALLATION
(23) Connect the negative cable to the battery. (1) Lubricate tappets.
(2) Install tappets and push rods in their original
VALVES AND VALVE SPRINGS positions. Ensure that the oil feed hole in the side of
the tappet body faces up (away from the crankshaft).
REMOVAL (3) Install aligning yokes with ARROW toward
(1) Remove the cylinder head. camshaft.
(2) Compress valve springs using Valve Spring (4) Install yoke retainer. Tighten the bolts to 23
Compressor Tool MD- 998772A. N-m (200 in. lbs.) torque. Install intake manifold.
(3) Remove valve retaining locks, valve spring (5) Install push rods in original positions.
retainers, valve stem seals and valve springs. (6) Install rocker arm.
(4) Before removing valves, remove any burrs from (7) Install cylinder head cover.
valve stem lock grooves to prevent damage to the (8) Install distributor, start engine and reset tim
valve guides. Identify valves to ensure installation in ing.
original location.
CAUTION: To prevent damage to valve mechanism,
INSTALLATION engine must not be run above fast idle until all
(1) Coat valve stems with lubrication oil and insert hydraulic tappets have filled with oil and have
them in cylinder head. become quiet.
(2) I f valves or seats are reground, check valve
stem height. I f valve is too long, replace cylinder
head. VIBRATION DA1PER
. (3) Install new seals on all valve guides. Install
REMOVAL
valve springs and valve retainers.
(4) Compress valve springs with Valve Spring (1) Disconnect the negative cable from the battery.
Compressor Tool MD-998772A, install locks and (2) Remove fan shroud retainer bolts and set
release tool. I f valves and/or seats are ground, mea shroud back over engine.
sure the installed height of springs. Make sure the (3) Remove the cooling system fan.
measurement is taken from bottom of spring seat in
(4) Remove the serpentine belt (refer to Group 7, (7) Position the fan shroud and install the bolts.
Cooling System). Tighten the retainer bolts to 11 N-m (95 in. lbs.)
(5) Remove the vibration damper pulley. torque.
(6) Remove vibration damper bolt and washer from (8) Connect the negative cable to the battery.
end of crankshaft.
(7) Install bar and screw from Puller Tool Set TIMING CHAIN COVER
C-3688. Install 2 bolts with washers through the
puller tool and into the vibration damper (Fig. 21). REMOVAL
System).
Cooling System).
(4) Remove water pump (refer to Group 7, Cooling
System).
(5) Remove power steering pump (refer to Group
19, Steering).
(7) Loosen oil pan bolts and remove the front bolt
at each side.
Fig. 21 Vibration Damper Assembly (8) Remove the cover bolts.
(8) Pull vibration damper off of the crankshaft. (9) Remove chain case cover and gasket using
INSTALLATION (10) Place a suitable tool behind the lips of the oil
(1) Position the vibration damper onto the crankshaft. seal to pry the oil seal outward. Be careful not to
(2) Place installing tool, part of Puller Tool Set damage the crankshaft seal surface of cover (Fig. 23).
C-3688 'in position and press the vibration damper
onto the crankshaft (Fig. 22).

INSTALLATION
Fig. 22 Installing Vibration Damper
(1) Be sure mating surfaces of chain case cover
(3) Install the crankshaft bolt and washer. Tighten and cylinder block are clean and free from burrs.
the bolt to 183 N-m (135 ft. lbs.) torque. (2) The water pump mounting surface must be
(4) Install the crankshaft pulley. Tighten the pul cleaned.
ley bolts to 23 N-m (200 in. lbs.) torque. (3) Using a new cover gasket, carefully install
(5) Install the serpentine belt (refer to Group 7, chain case cover to avoid damaging oil pan gasket.
Cooling System). Use a small amount of Mopar® Silicone Rubber Adhe
(6) Install the cooling system fan. Tighten the sive Sealant, or equivalent, at the joint between tim
bolts to 23 N-m (17 ft. lbs.) torque . ing chain cover gasket and the oil pan gasket. Finger
(4) Place the smaller diameter of the oil seal over (10) Remove the vibration damper bolt and seal
Front Oil Seal Installation Tool 6635 (Fig. 24). Seat installation tool.
the oil seal in the groove of the tool.
CRANKSHAFT v • INSTALL THIS
FRONT OIL END INTO
SEAL SPECIAL TOOL
6635
J9309-44

25).
(Fig.
(6) Tighten the 4 lower chain case cover bolts to J9309-46
13N-m (10 ft.lbs.) to prevent the cover from tipping

during seal installation. Fig. 26 Installing Oil Seal
OIL (11) Inspect the seal flange on the vibration damper.

SEAL (12) Install vibration damper.
(13) Install water pump and housing assembly
using new gaskets (refer to Group 7, Cooling Sys
tem). Tighten bolts to 41 N-m (30 ft. lbs.) torque.
(14) Install power steering pump (refer to Group
19, Steering).
(15) Install the serpentine belt (refer to Group 7,
Cooling System).
(17) Position the fan shroud and install the bolts.
Tighten the bolts to 11 N-m (95 in. lbs.) torque.
THING CHAIN
TIMING' REMOVAL
CHAIN
COVER J9309-45— (1) Remove Timing Chain Cover Refer to proce
dure in this section.
Fig. 25 Position Tool and Seal onto Crankshaft (2) Remove camshaft sprocket attaching bolt and
(7) Using the vibration damper bolt, tighten the remove timing chain with crankshaft and camshaft sprock
bolt to draw the seal into position on the crankshaft ets.
(Fig. 26). INSTALLATION
(8) Loosen the 4 bolts tightened in step 4 to allow (1) Place both camshaft sprocket and crankshaft
realignment of front cover assembly. sprocket on the bench with timing marks on exact imagi
(9) Tighten chain case cover bolts to 41 N-m (30 nary center line through both camshaft and crankshaft
ft.lbs.) torque. Tighten oil pan bolts to 24 N-m (215 bores.
in. lbs.) torque.
BR 5.9L ENGINE 9 -107

(2) Place timing chain around both sprockets. (7) Remove camshaft thrust plate, note location of
(3) Turn crankshaft and camshaft to line up with oil tab (Fig. 29).
shaft sprocket.
TIMING
J9409-97
MARKS THRUST PLATE
REAR SIDE
(6) Install the camshaft bolt. Tighten the bolt to 68 J9209-132
N-m (50 ft. lbs.) torque. Fig. 29 Timing Chain Oil Tab Installation
(8) Install a long bolt into front of camshaft to
facilitate removal of the camshaft. Remove camshaft,
thrust plate and up to 0.254 mm (0.010 inch) with a
cam lobes.
new thrust plate.
INSTALLATION
CAMSHAFT (1) Lubricate camshaft lobes and camshaft bearing
journals and insert the camshaft to within 51 mm (2
NOTE: The camshaft has an integral oil pump and
inches) of its final position in cylinder block.
distributor drive gear (Fig. 28).
NOTE: Whenever an engine has been rebuilt, a new cam
THRUST
shaft and/or new tappets installed, add 1 pint of Mopar
PLATE
Crankcase Conditioner, or equivalent. The oil mixture
PUMP A N D
should be left in engine for a minimum of 805 km (500
DISTRIBUTOR DRIVE miles). Drain at the next normal oil change.
GEAR INTEGRAL
WITH CAMSHAFT (2) Install Camshaft Gear Installer Tool C-3509
* CAMSHAFT SPROCKET with tongue back of distributor drive gear (Fig. 30).
J9309-71
Fig. 28 Camshaft and Sprocket Assembly

REMOVAL
(1) Remove intake manifold.
(3) Remove timing case cover and timing chain.
part so it can be installed in its original location. ^DRIVE GEAR ^J92oC84
(6) Remove distributor and lift out the oil pump
and distributor drive shaft. Fig. 30 Camshaft Holding Tool C-3509 (Installed Position)
I - 118 5 J L ENGINE
REHOWAL mm INSTALLATION fCorifinyed)

(3) Hold tool in position with a distributor lock- Tool C-3132-A) at back of each bearing shell. Drive
plate bolt. This tool will restrict camshaft from being out bearing shells (Fig. 32).
pushed in too far and prevent knocking out the welch
plug in rear of cylinder block. Tool should remain
installed u n t i l the camshaft and crankshaft
sprockets and t i m i n g chain have been installed,
(4) Install camshaft thrust plate and chain oil tab.
Make sure tang enters lower r i g h t hole i n
thrust plate, Tighten bolts to 24 N-m (210 In. lbs.)
torque. Top edge of tab should be flat against thrust
plate in order to catch oil for chain lubrication.
sprocket on the bench with timing marks on exact imagi
nary center line through both camshaft and crankshaft
Fig. 32 Camshaft Bearings Removal/Installation with
bores.
Tool C-3132-A
(7) Turn crankshaft and camshaft to line up with INSTALLATION
keyway location in crankshaft sprocket and in cam (1) Install new camshaft bearings with Camshaft
shaft sprocket. Bearing Remover/Installer Tool C-3132-A by sliding
(8) Lift sprockets and chain (keep sprockets tight the new camshaft bearing shell over proper adapter.
against the chain in position as described). (2) Position rear bearing in the tool. Install horse
(9) Slide both sprockets evenly over their respec shoe lock and by reversing removal procedure, care
tive shafts and use a straightedge to check alignment fully drive bearing shell into place.
of timing marks (Fig. 31). (3) Install remaining bearings in the same manner.
Bearings must be carefully aligned to bring oil holes into
full register with oil passages from the main bearing. If the
camshaft bearing shell oil holes are not in exact alignment,
remove and install them correctly. Install a new core hole
plug at the rear of camshaft. Be sure this plug does not
leak.
CAMSHAFT BEARINGS
REMOVAL
NOTE: This procedure requires that the engine is

Fig, 81 Alignment of Timing Marks removed from the vehicle.
(10) Install the camshaft bolt/cup washer. Tighten
bolt to 68 N-m (50 ft. lbs.) torque. (1) With engine completely disassembled, drive out
(11) Measure camshaft end play. Refer to Specifica rear cam bearing core hole plug.
tions for proper clearance. I f not within limits install (2) Install proper size adapters and horseshoe
a new thrust plate. washers (part of Camshaft Bearing Remover/Installer
(12) Each tappet reused must be installed in the same Tool C-3132-A) at back of each bearing shell. Drive
position from which it was removed. When camshaft is out bearing shells (Fig. 33).
replaced, all of the tappets must be replaced.
CAMSHAFT BEARINGS
REMOVAL
NOTE: This procedure requires that the engine is

removed from the vehicle.
(1) With engine completely disassembled, drive out

rear cam bearing core hole plug.
(2) Install proper size adapters and horseshoe
washers (part of Camshaft Bearing Remover/Installer Fig. 33 Camshaft Bearings Removal/Installation with
Tool C-3132-A .
BR 5 J L ENGINE 9 -109
R E M O V A L AHP §li8YALLAT§©ti (Continued)
INSTALLATION (5) Install the dowels in the cylinder block (Fig. 35).
(1) Install new camshaft bearings with Camshaft
DOWEL ^^^^s. DOWEL
Bearing Remover/Installer Tool C-3132-A by sliding
the new camshaft bearing shell over proper adapter.
(2) Position rear bearing in the tool. Install horse
shoe lock and by reversing removal procedure, care
OIL PAN
REMOVAL
(2) Remove engine oil dipstick.
(3) Raise vehicle.
(4) Drain engine oil.
J9309-79
(5) Remove exhaust pipe.
(8) Remove left engine to transmission strut.
Fig. 85 Position of Dowels in Cylinder Block
(7) Loosen the right side engine support bracket
cushion thru-bolt nut and raise the engine slightly. (6) Apply small amount of Mopar® Silicone Rubber
Remove oil pan by sliding backward and out. Adhesive Sealant, or equivalent in the corner of the
(8) Remove the one-piece gasket. cap and the cylinder block.
(7) Slide the one-piece gasket over the dowels and
INSTALLATION onto the block.
(1) Clean the block and pan gasket surfaces. (8) Position the oil pan over the dowels and onto
(2) Trim or remove excess sealant film in the rear the gasket.
main cap oil pan gasket groove. DO MOT remove (9) Install the oil pan bolts. Tighten the bolts to 24
the sealant inside the rear m a i n cap slots. N-m (215 in. lbs.) torque.
(3) I f present, trim excess sealant from Inside the (10) Remove the dowels. Install the remaining oil
engine. pan bolts. Tighten these bolts to 24 N-m (215 in. lbs.)
(4) Fabricate 4 alignment dowels from 5/16 x 1 1/2 torque.
inch bolts. Cut the head off the bolts and cut a slot (11) Lower the engine into the support cushion
into the top of the dowel. This will allow easier brackets and tighten the thru bolt nut to the proper
installation and removal with a screwdriver (Fig. 34). torque.
^ 5 / 1 6 " x 17 " BOLT
(12) Install the drain plug. Tighten drain plug to
2

(14) Install exhaust pipe.
(15) Lower vehicle.
(16) Install dipstick.
DOWEL (17) Connect the negative cable to the battery.
A CRANKSHAFT I A I N BEARINGS
SLOT J9509-163
REMOVAL
ing cap.
. (3) identify bearing caps before removal. Remove
bearing caps one at a time.

(4) Remove upper half of bearing by inserting (6) Pistons and connecting rods must be removed
Crankshaft Main Bearing . Remover/Installer Tool from top of cylinder block. When removing piston and
C-3059 into the oil hole of crankshaft (Fig. 36). connecting rod assemblies, rotate crankshaft to cen
(5) Slowly rotate crankshaft clockwise, forcing out ter the connecting rod in the cylinder bore and at
upper half of bearing shell. BDC. Be careful not to nick crankshaft journals.
ing rod.
INSTALLATION
(1) Be sure that compression ring gaps are stag
gered so that neither is in-line with oil ring rail gap.
(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located properly (Fig. 37).
OIL RING
SPACER GAP
SECOND
COMPRESSION
TOP
RING GAP
COMPRESSION
RING GAP OIL RING RAIL
Fig. 86 Upper Main Bearing Removal and GAP (TOP)
INSTALLATION
OIL RING RAIL
procedures are to be cleaned and oiled before instal
lation.
When installing a new upper bearing shell, slightly Fig. 37 Proper Ring Installation
chamfer the sharp edges from the plain side. (3) Immerse the piston head and rings i n clean
(1) Start bearing in place, and insert Crankshaft engine oil. Slide Piston Ring Compressor Tool C-385
Main Bearing Remover/Installer Tool C-3059 into oil over the piston and tighten with the special wrench
hole of crankshaft (Fig. 36). (part of Tool C-385). Be sure position of rings
(2) Slowly rotate crankshaft counterclockwise slid does not change during this operation.
ing the bearing into position. Remove Tool C-3059. (4) Install connecting rod bolt protectors on rod
(3) Install the bearing cap. Clean and oil the bolts. bolts, the long protector should be installed on the
Tighten the capbolts to 115 N-m (85 ft. lbs.) torque. numbered side of the connecting rod.
(4) Install the oil pump. (5) Rotate crankshaft so that the connecting rod
(5) Install the oil pan. journal is on the center of the cylinder bore. Be sure
connecting rod and cylinder bore number are the
PISTON AND CONNECTING HOD ASSEMBLY same. Insert rod and piston into cylinder bore and
guide rod over the crankshaft journal.
REMOVAL
(6) Tap the piston down in cylinder bore, using a
(1) Remove the engine from the vehicle.
hammer handle. At the same time, guide connecting
(2) Remove the cylinder head. rod into position on crankshaft journal.
(7) The notch or groove on top of piston must be
(4) Remove top ridge of cylinder bores with a reli
pointing toward front of engine. The larger chamfer
able ridge reamer before removing pistons from cyl
of the connecting rod bore must be installed toward
inder block. Be sure to keep tops of pistons covered crankshaft journal fillet.
during this operation.
(8) Install rod caps. Be sure connecting rod, con
(5) Be sure the connecting rod and connecting rod
necting rod cap and cylinder bore number are the
cap are identified with the cylinder number. Remove same. Install nuts on cleaned and oiled rod bolts and
connecting rod cap. Install connecting rod bolt guide tighten nuts to 61 N-m (45 ft. lbs.) torque.
set on connecting rod bolts.
BR
5.9L ENGINE 9 -111
R E M O V A L AND I N S T A L L A T I O N ( C o n t i n u e d )
(10) Install the cylinder head. Journal grinding should not exceed 0.305 mm
(11) Install the engine into the vehicle. (0.012 Inch) under the standard journal diameter. DO
CRANKSHAFT NOT nick crank pin or bearing fillets. After grinding,
A crankshaft which has undersize journals will be remove rough edges from crankshaft oil holes and
stamped with 1/4 inch letters on the milled flat on clean out all oil passages.
the No.3 crankshaft counterweight (Fig. 38).
FOR EXAMPLE: R2 stamped on the No.3 crank CAUTION; After any journal grind, it is important
shaft counterweight indicates that the No.2 rod jour that the final paper or cloth polish be in the same
nal Is 0.025 mm (0.001 in) undersize. M4 indicates direction as the engine rotates.
that the No.4 main journal is 0.025 mm (0.001 In)
undersize. R3 M2 indicates that the No.3 rod journal
CLEANING
and the No.2 main journal are 0.025 mm (0.001 in)
Clean Loctite 518 residue and sealant from the cyl
undersize.
inder block and rear cap mating surface. Do this
before applying the Loctite drop and the installation
of rear cap.
Undersize Journal Identification Stamp
0.025 m m (0.001 inch) (Rod) R1-R2-R3 or R4
INSTALLATION
0.025 m m (0.001 inch) (Main) M1-AA2-M3-AA4 or AA5
oil.
M" LETTERS- (ROD)
VM-I^(MAIN) the white paint facing towards the rear of the engine.
oil.
the rear of the engine.
J9309-52 (6) Apply 5 mm (0.20 in) drop of Loctite 518, or
Fig. 38 Location of Crankshaft Identification (Fig. 39). DO NOT over apply sealant or allow the
When a crankshaft Is replaced, all main and con sealant to contact the rubber seal. Assemble bearing
cap to cylinder block Immediately after sealant appli
necting rod bearings should be replaced with new
cation.
replaced.
REMOVAL
ing cap.
(3) Remove the vibration damper.
(4) Remove the timing chain cover.
(5) Identify bearing caps before removal. Remove
bearing caps and bearings one at a time.
(6) Lift the crankshaft out of the block.
(7) Remove and discard the crankshaft rear oil
.25 DROP OF LOCTITE 515
seals. O N BOTH SIDES OF
(8) Remove and discard the front crankshaft oil REAR MAIN CAP J9509-75
seal.
INSPECTION OF JOURNALS
The crankshaft connecting rod and main journals ment dowel and cap bolts. DO NOT remove excess
should be checked for excessive wear, taper and scor material after assembly. DO NOT strike rear cap
ing. The maximum taper or out-of-round on any more than 2 times for proper engagement.
crankshaft journal Is 0.025 mm (0.001 inch).
9 -112 5.9L ENGINE BR
REMOWAL AND INSTALLATION ( C o n t i n u e d )

(8) Clean and oil all cap bolts. Install all main interference. I f tool does not fit, the cover must be
bearing caps. Install all cap bolts and alternately removed and installed properly.
tighten to 115 N-m (85 ft. lbs.) torque. (4) Place a suitable tool behind the lips of the oil
(9) Install oil pump. seal. to pry the oil seal outward. Be careful not to
Apply Mopar® Silicone Rubber Adhesive Sealant, damage the crankshaft seal bore of cover.
or equivalent, at bearing cap to block joint to provide (5) Place the smaller diameter of the oil seal over
cap to block and oil pan sealing (Fig. 40). Apply Front Oil Seal Installation Tool 6635 (Fig. 41). Seat
enough sealant until a small amount is squeezed out. the oil seal in the groove of the tool.
CRANKSHAFT
pan seal groove. FRONT OIL
(10) Install new front crankshaft oil seal. SEAL
Fig. 41 Placing Oii Seal on Installation Tool 6635

(Fig. 42).
Fig. 40 Apply Sealant to Bearing Cap to Block Joint
Oil PUMP
REMOVAL
(2) Remove the oil pump from rear main bearing
cap.
INSTALLATION
(1) Install oil pump. During installation slowly
rotate pump body to ensure driveshaft-to-pump rotor
shaft engagement.
(2) Hold the oil pump base flush against mating
surface on No.5 main bearing cap. Finger tighten
pump attaching bolts. Tighten attaching bolts to 41
FRONT CRANKSHAFT OIL SEAL

The oil seal can be replaced without removing the
COVER J9309-45^
timing chain cover provided the cover is not mis
aligned. Fig. 42 Position Tool and Seal onto Crankshaft
(2) Remove vibration damper. (7) Using the vibration damper bolt, tighten the
(3) I f front seal is suspected of leaking, check front bolt to draw the seal into position on the crankshaft
oil seal alignment to crankshaft. The seal installa (Fig. 43).
tion/alignment tool 6635, should fit with minimum (8) Remove the vibration damper bolt and seal
installation tool.
ftEHOWAL ANP I N S T A L L A T I O N fContinued)
.25 DROP OF LOCTITE 515

ON BOTH SIDES OF
REAR MAIN CAP J9509-75
J9309-46 Fig. 44 Sealant Application to Bearing Cap
Fig. 43 Installing Oil Seal (9) To align the bearing cap, use cap slot, align
(9) Inspect the seal flange on the vibration material after assembly. DO NOT strike rear cap
damper. more than 2 times for proper engagement.
(10) Install the vibration damper. (10) Clean and oil all cap bolts. Install all main
(11) Connect the negative cable to the battery. bearing caps. Install all cap bolts and alternately
CRANKSHAFT REAR OIL SEALS (11) Install oil pump.
The service seal is a 2 piece, viton seal. The upper (12) Apply Mopar® Silicone Rubber Adhesive Seal
seal half can be installed with crankshaft removed ant, or equivalent, at bearing cap to block joint to
from engine or with crankshaft installed. When a provide cap to block and oil pan sealing (Fig. 45).
new upper seal is installed, install a new lower seal. Apply enough sealant until a small amount is
The lower seal half can only be installed with the squeezed out. Withdraw nozzle and wipe excess seal
rear main bearing cap removed. ant off the oil pan seal groove.
UPPER SEAL REPLACEMENT—CRANKSHAFT MOPAR SILICONE SEALANT
REMOVED RUBBER ADHESIVE APPLIED
(1) Remove the crankshaft. Discard the old upper
seal.
face. Make sure the seal groove is free of debris.
oil
oil.
the rear of the engine. Fig. 45 Apply Sealant to Bearing Cap to Block Joint
(8) Apply 5 mm (0.20 in) drop of Loctite 518, or
equivalent, on each side of the rear main bearing cap (13) Install new front crankshaft oil seal.
R E M O V A L A N D INSTALLATION gConfinueci)
UPPER SEAL REPLACEMENT—CRANKSHAFT (6) Lightly oil the new lower seal lips with engine
INSTALLED oil.
(1) Remove the oil pan. (7) Install a new lower seal in bearing cap with
(2) Remove the oil pump from the rear main bear white paint facing the rear of engine.
ing cap. (8) Apply 5 mm (0.20 in) drop of Loctite 518, or equiva
(3) Remove the rear main bearing cap. Remove lent, on each side of the rear main bearing cap (Fig. 44).
and discard the old lower oil seal. DO NOT over apply sealant or allow the sealant to contact
(4) Carefully remove and discard the old upper oil the rubber seal. Assemble bearing cap to cylinder block
seal. immediately after sealant application.
(5) Clean the cylinder block mating surfaces before (9) To align the bearing cap, use cap slot, align
oil seal installation. ment dowel and cap bolts. DO NOT remove excess
(6) Lightly oil the new upper seal lips with engine material after assembly DO NOT strike rear cap
oil. To allow ease of installation of the seal, loosen at more than 2 times for proper engagement.
least the 2 main bearing caps forward of the rear (10) Install the rear main bearing cap with
bearing cap. cleaned and oiled cap bolts. Alternately tighten the
(7) Rotate the new upper seal into the cylinder cap bolts to 115 N-m (85 ft. lbs.) torque.
block being careful not to shave or cut the outer sur (11) Install oil pump.
face of the seal. To assure proper installation, use the (12) Apply Mopar® Silicone Rubber Adhesive Seal
installation tool provided with the kit. Install the ant, or equivalent, at bearing cap to block joint to
new seal with the white paint facing towards the provide cap to block and oil pan sealing (Fig. 45).
rear of the engine. Apply enough sealant until a small amount is
(8) Install the new lower rear bearing oil seal into squeezed out. Withdraw nozzle and wipe excess seal
the bearing cap with the white paint facing towards ant off the oil pan seal groove.
the rear of the engine. (13) Immediately install the oil pan.
(9) Apply 5 mm (0.20 in) drop of Loctite 518, or equiva
lent, on each side of the rear main bearing cap (Fig. 44). ENGINE CORE PLUGS
DO NOT over apply sealant or allow the sealant to contact Engine core plugs have been pressed into the oil
the rubber seal. Assemble bearing cap to cylinder block galleries behind the camshaft thrust plate (Fig. 46).
immediately after sealant application. Be sure the white This will reduce internal leakage and help maintain
paint faces toward the rear of the engine. higher oil pressure at idle.
more than 2 times for proper engagement.
(11) Install the rear main bearing cap with cleaned
and oiled cap bolts. Alternately tighten ALL cap bolts
(13) Apply Mopar® Silicone Rubber Adhesive Seal
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 45)
(Fig. 8). Apply enough sealant until a small amount
is squeezed out. Withdraw nozzle and wipe excess
sealant off the oil pan seal groove.
LOWER SEAL REPLACEMENT

ing cap.
Fig. 46 Location of Cup Plugs in Oil Galleries
(3) Remove the rear main bearing cap and discard
the old lower seal. REMOWAL
(4) Clean the rear main cap mating surfaces (1) Using a blunt tool such as a drift or a screw
including the oil pan seal grooves. driver and a hammer, strike the bottom edge of the
(5) Carefully install a new upper seal (refer to cup plug (Fig. 47).
Upper Seal Replacement - Crankshaft Installed pro (2) With the cup plug rotated, grasp firmly with pliers
cedure above). or other suitable tool and remove plug (Fig. 47).
BR 5JL ENGINE I -115

CYLINDER ASSEMBLE
(1) Clean all tappet parts in a solvent that will
remove all varnish and carbon.
(2) Replace tappets that are unfit for further ser
vice with new assemblies.
(3) I f plunger shows signs of scoring or wear,
install a new tappet assembly. I f valve is pitted, or
ing, install a new tappet assembly.
(4) Assemble tappets (Fig. 48).
DRIFT 9209-41

CLEANING
Thoroughly clean inside of cup plug hole in cylin
SPRING CAP J9109-220
der block or head. Be sure to remove old, sealer.
Make certain the new plug is cleaned of all oil or grease. Fig. 48 Hydraulic Tappet Assembly
CYLINDER B L 0 C I
INSTALLATION
(1) Coat edges of plug and core hole with Mopar DISASSEMBLE
Gasket Maker, or equivalent. (1) Remove the cylinder head.
CAUTION; DO NOT drive cup plug into the casting (3) Remove the piston/connecting rod assembly.
as restricted coolant flow can result and cause seri
ous engine problems, OIL LINE PLUG
The oil line plug is located in the vertical passage at the
rear of the block between the Oil-To-Filter and Oil-From-
Filter passages (Fig. 49). Improper installation or plug
0.50 mm (0.020 inch) inside the lead-in chamfer.
missing could cause erratic, low or no oil pressure.
(3) I t is not necessary to wait for curing of the (1) Remove oil pressure sending unit from back of block.
sealant. The cooling system can be filled and the (2) Insert a 3.175 mm (1/8 inch) finish wire or
vehicle placed in service immediately. equivalent into passage.
DISASSEMBLY AND A S S E M B L Y 7-11/16 inches) from machined surface of block (Fig.
49). I f plug is too high, use a suitable flat dowel drift
HYDRAULIC TAPPETS to position properly.
CAUTION: The plunger and tappet bodies are not RIGHT OIL GALLERY
DISASSEMBLE
(1) Pry out plunger retainer spring clip (Fig. 48).
(2) Clean varnish deposits from inside of tappet
body above plunger cap.
(3) Invert tappet body and remove plunger cap,
plunger, check valve, check valve spring, check valve
retainer and plunger spring (Fig. 48). Check valve J9109-229
could be flat or ball. Fig. 49 Oii Line Plug

9 - 116 5.9L ENGINE

(4) I f plug Is too low, remove oil pan and rear main
bearing cap. Use suitable flat dowel to properly pos-
tion. Coat outside diameter of plug with Mopar®
(stud and bearing mount adhesive), or equivalent.
Plug should be 54.0 to 57.7 mm (2-1/8 to 2-5/16
inches) from bottom of the block.
(5) Assemble engine and check oil pressure.
ASSEMBLE
(1) Install the piston/connecting rod assembly.
WALWE SEIWICE
Fig. 51 Measuring Waive Guide Wear
VALVE CLEANING
Clean valves thoroughly. Discard burned, warped
and cracked valves. learner O/S Valve Guide Size
Remove carbon and varnish deposits from inside of
valve guides with a reliable guide cleaner. 0.076 mm 8.026 - 8.052 mm
(0.003 in.) (0.316-0.317 in.)
VALVE INSPECTION 8.331 -8.357 mm
0.381 mm
Measure valve stems for wear. I f wear exceeds (0.015 in.) (0.328 - 0.329 in.
0.051 mm (0.002 inch), replace the valve.
WALWE Q P f P E S
Measure valve stem guide clearance as follows: J9309-30
(1) Install Valve Guide Sleeve Tool C-3973 over Fig. 52 Reamer Sizes
valve stem and install valve (Fig. 50). The special Slowly turn reamer by hand and clean guide thoroughly
sleeve places the valve at the correct height for before installing new valve. Ream the valve guides from
checking with a dial indicator. standard to 0.381 mm (0.015 inch). Use a 2 step pro
cedure so the valve guides are reamed true in rela
tion to the valve seat:
REFACING WALWES AMD WALWE S E A T S

The intake and exhaust valves have a 43-1/4°
to 43-3/4°
face angle and a 44-1/4° to 44-3/4° seat angle (Fig. 53).
VALVES
Fig. 50 Positioning Waive with Tool C-3973 VALVE SEATS
(2) Attach Dial Indicator Tool C-3339 to cylinder CAUTION: D O NOT un-shroud valves during valve
head and set it at right angle of valve stem being seat refacing ( F i g . 55).
measured (Fig. 51).
(3) Move valve to and from the indicator. The total (1) When refacing valve seats, it is important that the
dial indicator reading should not exceed 0.432 mm correct size valve guide pilot be used for reseating stones. A
(0.017 inch). Ream the guides for valves with over true and complete surface must be obtained.
size stems i f dial indicator reading is excessive or i f (2) Measure the concentricity of valve seat using a
the stems are scuffed or scored. dial indicator. Total runout should not exceed 0.051
Service valves with oversize stems are available mm (0.002 inch) total indicator reading.
(Fig. 52). (3) Inspect the valve seat with Prussian blue to deter
mine where the valve contacts the seat. To do this, coat
BR 5 J L ENGINE 9 -117

CONTACT
POINT REFACING STONE
457/ - 457/
/ MUST NOT CUT
/ / VALVE SHROUD
VALVE SEAT RK635
A - SEAT WIDTH - INTAKE 1.016- 1.524 mm (0.040 - 0.060 in.)

Fig. 55 Refacing Valve Seats
EXHAUST 1.524 - 2.032 mm (0.060 - 0.080 in.) be tested. As an example the compression length of
B - FACE ANGLE (INTAKE & EXHAUST) 4 3 7 / - 4 3 7 /
C - SEAT ANGLE (INTAKE & EXHAUST) 4 4 7 / - 4 4 7 / the spring to be tested is 1-5/16 inch. Turn table of
D - CONTACT SURFACE Universal Valve Spring Tester Tool until surface is in
line with the 1-5/16 inch mark on the threaded stud.
J9309-95
Be sure the zero mark is to the front (Fig. 56). Place
Fig. 53 Vaive Face and Seat Angles spring over stud on the table and lift compressing
lever to set tone device. Pull on torque wrench until
JL
ping is heard. Take reading on torque wrench at this
instant. Multiply this reading by 2. This will give the
INTAKE EXHAUST
spring load at test length. Fractional measurements
VALVE VALVE
FACE' are indicated on the table for finer adjustments.
Refer to specifications to obtain specified height and
allowable tensions. Discard the springs that do not
- STEM *
TORQUE
WRENCH
VALVE SPRING
RETAINER LOCK
GROOVE
J9209-127
Fig. 54 Intake and Exhaust Valves VALVE SPRING

TESTER
valve seat LIGHTLY with Prussian blue then set valve
in place. Rotate the valve with light pressure. I f the
blue is transferred to the center of valve face, contact
is satisfactory. I f the blue is transferred to the top 9509-79
edge of valve face, lower valve seat with a 15° stone.
Fig. 56 Testing Vaive Spring for Compressed Length
I f the blue is transferred to bottom edge of valve face
raise valve seat with a 60° stone. OIL P U i P
intake seats should be 1.016-1.524 mm (0.040-0.060 DISASSEMBLE
inch). The width of the exhaust seats should be (1) Remove the relief valve as follows:
1.524-2.032 mm (0.060-0.080 inch). (a) Remove cotter pin. Drill a 3.175 mm (1/8
inch) hole into the relief valve retainer cap and
WAIVE S P R I N G INSPECTION insert a self-threading sheet metal screw.
Whenever valves have been removed for inspection, (b) Clamp screw into a vise and while support
reconditioning or replacement, valve springs should ing oil pump, remove cap by tapping pump body
9 -118 5.9L ENGINE BR
using a soft hammer. Discard retainer cap and Clean cylinder block front and rear gasket surfaces
remove spring and relief valve (Fig. 57). using a suitable solvent.
INSPECTION
exceeds 0.00075 mm/mm (0.00075 inch/inch) times
the span length in inches in any direction, either
replace head or lightly machine the head surface.
FOR EXAMPLE: A 305 mm (12 inch) span is 0.102
mm (0.004 inch) out-of-flat. The allowable out-of-flat
is 305 X 0.00075 (12 X 0.00075) equals 0.23 mm
(0.009 inch). This amount of out-of-flat is acceptable.
The cylinder head surface finish should be
1.78-3.00 microns (70-125 microinches).
PISTON AND CONNECTING iOD ASSEMBLY-
Fig. 57 Oil Pressure Relief Valve INSPECTION

Check the crankshaft connecting rod journal for
(.2) Remove oil pump cover (Fig. 58). excessive wear, taper and scoring.
(3) Remove pump outer rotor and inner rotor with Check the cylinder block bore for out-of-round,
shaft (Fig. 58). taper, scoring and scuffing.
(4) Wash all parts in a suitable solvent and inspect Check the pistons for taper and elliptical shape
carefully for damage or wear. before they are fitted into the cylinder bore (Fig. 59).
INNER ROTOR DISTRIBUTOR DRIVESHAFT
PISTON PIN BORE DIAMETER
Fig. 58 Oil Pump

ASSEMBLE
(1) Install pump rotors and shaft, using new parts
as required.
(2) Position the oil pump cover onto the pump body.
Tighten cover bolts to 11 N-m (95 in. lbs.) torque.
(3) Install the relief valve and spring. Insert the
cotter pin.
(4) Tap on a new retainer cap. PISTON A DIA = PISTON DIAMETER BORE DIAMETER
(5) Prime oil pump before installation by filling r
A
rotor cavity with engine oil. B 101.580 (3.9992) 101.592 (3.9997) 101.605 (4.0002) 101.618(4.0007)
C 101.592 (3.9997) 101.605 (4.0002) 101.618(4.0007) 101.630 (4.0012)
D 101.605 (4.0002) 101.618(4.0007) 101.630 (4.0012) 101.643 (4.0017)
CLEANING AND INSPECTION E
J9509-79
CYLINDER HEAD ASSEMBLY Fig. 59 Piston Measurements
CLEANING
Clean all surfaces of cylinder block and cylinder heads.
BR 5.9L ENGINE I - 119
OIL PAN
CLEMMING
Trim, or remove excess sealant film in the rear
the sealant inside the rear m a i n cap slots.
engine.
Clean oil pan in solvent and wipe dry with a clean
cloth.
Clean oil screen and pipe thoroughly in clean sol
vent. Inspect condition of screen. RH176
INSPECTION
Inspect oil drain plug and plug hole for stripped or Fig. 61 Measuring Outer Rotor Thickness
OIL P U i P
INSPECTION
or grooved.
(Fig. 60). I f a 0.038 mm (0.0015 inch) feeler gauge
can be inserted between cover and straightedge,
pump assembly should be replaced.
RHl 77
STRAIGHT E D G E
COWER Fig. 62 Measuring Inner Rotor Thickness
Slide outer rotor into pump body. Press rotor to the side
with your fingers and measure clearance between rotor and
pump body (Fig. 63). If clearance is 0.356 mm (0.014 inch)
or more, replace oil pump assembly.

OUTER ROTOR
Measure thickness and diameter of OUTER rotor.
If outer rotor thickness measures 20.9 mm (0.825 PUHP BODY
inch) or less or i f the diameter is 62.7 mm (2.469
inches) or less, replace outer rotor (Fig. 61).
If inner rotor measures 20.9 mm (0.825 inch) or Fig. 63 Measuring Outer Rotor Clearance in
less, replace inner rotor and shaft assembly (Fig. 62). Housing
CLEANING A N D INSPECTION (Continued)
Install inner rotor and shaft into pump body. I f Inspect oil pressure relief valve plunger for scoring
clearance between inner and outer rotors is 0.203 and free operation in its bore. Small marks may be
mm (0.008 Inch) or more, replace shaft and both removed with 400-grit wet or dry sandpaper.
rotors (Fig. 64). The relief valve spring has a free length of approx
imately 49.5 mm (1.95 inches). The spring should
test between 19.5 and 20.5 pounds when compressed
to 34 mm (1-11/32 inches). Replace spring that fails
to meet these specifications (Fig. 66).
If oil pressure was low and pump Is within specifi
Fig. 64 Measuring Ciearance Between Rotors

(0.004 inch) or more can be inserted between rotors RN98
65).
Fig. 66 Proper Installation of Retainer Cap
CYLINDER B L 0 C I
CLEANING
INSPECTION
round and taper with Cylinder Bore Indicator Tool
C-119. The cylinder block should be bored and honed
with new pistons and rings fitted if:
(0.005 inch) out-of-round.
0.254 mm (0.010 inch).
Fig. 65 Measuring Clearance Over Rotors Boring and honing operation should be closely coor
dinated with the fitting of pistons and rings so spec
ified clearances may be maintained.
Refer to Standard Service Procedures in the begin
ning of this Group for the proper honing of cylinder
bores.
SPECIFICATIONS
5.9L ENGINE
Camshaft End Play 0.051 -0.178 mm
(0.002 - 0.007 in)
Bearing Diameter Max. Allowable ....0.254 mm
No. 1 .............50.800-50.825 mm (0.010 in)
(2.000 - 2.001 in) Main Bearing Journals
No. 2 . 5 0 . 3 9 4 - 5 0 . 4 1 9 mm Diameter.... 71.361 - 71.387 mm
(1.984- 1.985 in) (2.8095-2.8105 in)
No. 3 50.013 - 50.038 mm Out-of-Round (Max.) 0.0254 mm
(1.969- 1.970 in) (0.001 in)
No. 4 .49.606 - 49.632 mm Taper (Max.) 0.0254 mm
(1.953- 1.954 in) (0.001 in)
No. 5... 39.688 - 39.713 mm
(1.5625 - 1.5635 in) Cylinder Block
Diametrical Clearance .0.0254 - 0.0762 mm
(0.001 - 0.003 in) Cylinder Bore
Max. Allowable 0.127 mm Diameter.. ....101.60 - 101.65 mm
(0.005 in) (4.000 - 4.002 in)
End Play 0.051 - 0.254 mm Out-of-Round (Max.) ....0.127 mm
( 0 . 0 0 2 - 0 . 0 1 0 in) (0.005 in)
Bearing Journal Diameter Taper (Max.) 0.254 mm
No. 1 50.749 - 50.775 mm (0.010 in)
(1.998- 1.999 in) Distributor Lower Drive Shaft
No. 2 50.343 - 50.368 mm Bushing (Press Fit in Block) 0.0127 - 0.3556 mm
(1.982 - 1.983 in) (0.0005-0.0140 in)
No. 3 49.962 - 49.987 mm Shaft-to-Bushing Clearance 0.0178 - 0.0686 mm
(1.967- 1.968 in) (0.0007 - 0.0027 in)
No. 4 49.555 - 49.581 mm Tappet Bore Diameter 22.99 - 23.01 mm
(1.951 - 1.952 in) (0.9051 - 0.9059 in)
No. 5 39.637 - 39.662 mm
(1.5605 - 1.5615 in) Cylinder Head
Connecting Rods Compression Pressure 689 kPa

(100 psi)
Bearing Clearance. 0.013 - 0.056 mm Gasket Thickness (Compressed) 1.2065 mm
(0.0005 - 0.0022 in) (0.0475 in)
Max. Allowable .0.08 mm (.003 in) Valve Seat
Piston Pin Bore Diameter... 24.966 - 24.978 mm Angle 44.25° - 44.75°
(0.9829 - 0.9834 in) Runout (Max.) 0.0762 mm
Side Clearance (Two Rods).. 0.1 52 - 0.356 mm (0.003 in)
( 0 . 0 0 6 - 0 . 0 1 4 in) Width (Finish) - Intake 1.016 - 1.524 mm
Total Weight (Less Bearing).... ...758 grams (0.040 - 0.060 in)
(25.74 oz) Width (Finish) - Exhaust 1.524 - 2.032 mm
(0.060 - 0.080 in)
Crankshaft
Hydraulic Tappets
Connecting Rod Journal
Diameter. 53.950 - 53.975 mm Body Diameter ...22.949 - 22.962 mm
(2.124-2.125 in) (0.9035 - 0.9040 in)
Out-of-Round (Max.) 0.0254 mm Clearance in Block 0.0279 - 0.0610 mm
(0.001 in) (0.0011 - 0.0024 in)
Taper (Max.) .0.0254 mm Dry Lash 1.524 - 5.334 mm
(0.001 in) (0.060-0.210 in)
Diametrical Clearance Push Rod Length 175.64 - 176.15 mm
No. 1 0.013 - 0.038 mm (6.915-6.935 in)
(0.0005-0.0015 in)
Max. Allowable (No. 1)... 0.0381 mm
(0.0015 in)
Nos. 2, 3, 4 and 5 0.013 - 0.051 mm
(0.005 - 0.0020 in)
Max. Allowable (Nos. 2, 2, 4 & 5) 0.064 mm
(0.0025 in) J9509-68
9 • 122 5.9L ENGINE BR
Oil Pump Piston Rings
Clearance over Rotors (Max.) 0.1016 mm Ring Gap

(0.004 in) Compression Ring (Top) 0.30 - 0.55 mm
Cover Out-of-Flat (Max.) 0.0381 mm ( 0 . 0 1 2 - 0 . 0 2 2 in)
(0.0015 in) Compression Rings (2nd) 0.55 - 0.80 mm
Inner Rotor Thickness (Min.) 20.955 mm ( 0 . 0 2 2 - 0 . 0 3 1 in)
(0.825 in) Oil Control (Steel Rails) 0.381 - 1.397 mm
Outer Rotor ( 0 . 0 1 5 - 0 . 0 5 5 in)
Clearance (Max.) 0.3556 mm Ring Side Clearance
(0.014 in) Compression Rings 0.040 - 0.085 mm
Diameter (Min.) 62.7126 mm ( 0 . 0 0 1 6 - 0 . 0 0 3 3 in)
(2.469 in) Oil Ring (Steel Rails) 0.05 - 0.21 mm
Thickness (Min.) 20.955 mm (0.002 - 0.008 in)
(0.825 in) Ring Width
Tip Clearance between Rotors (Max.) 0.2032 mm Compression Rings 1.530 - 1.555 mm
(0.008 in) ( 0 . 0 6 0 - 0 . 0 6 1 in)
Oil Ring (Steel Rails) - Max. 0.447 - 0.473 mm
Oil Pressure ( 0 . 0 1 8 - 0 . 0 1 9 in)
At Curb Idle Speed (Minimum)* 41.4 kPa Valves

(6 psi)
At 3000 rpm 207 - 552 kPa Face Angle 43.25° - 43.75°
(30 - 80 psi) Head Diameter
Switch Actuating Pressure (Min.) 34.5 - 48.3 kPa Intake 47.752 mm
(5-7 psi) (1.88 in)
* CAUTION: If pressure is ZERO at curb idle, DO NOT Exhaust 41.072 mm
run engine at 3,000 rpm. (1.617 in)
Length (Overall)
Oil Filter Intake 126.21 - 126.85 mm
Bypass Valve Setting.. 62 -103 kPa (4.969 - 4.994 in)
(9-15 psi) Exhaust 126.44 - 127.30 mm
( 4 . 9 7 8 - 5 . 0 1 2 in)
Pistons Lift (Zero Lash) 10.414 mm
(0.410 in)
Clearance at Top of Skirt 0.01 3 - 0.038 mm Stem Diameter
(0.0005-0.0015 in) Intake 9.449 - 9.474 mm
Land Clearance (Diametrical) ..................... 0.508 - 0.660 mm (0.372 - 0.373 in)
(0.020 - 0.026 in) Exhaust 9.423 - 9.449 mm
Piston Length 81.03 mm (0.371 - 0.372 in)
(3.19 in) Stem-to-Guide Clearance
Piston Ring Groove Depth Intake 0.0254 - 0.0762 mm
Nos.l and 2 4.761 -4.912 mm (0.001 - 0.003 in)
(0.187-0.193 in) Exhaust 0.0508 - 0.1016 mm
No.3 3 . 9 9 6 - 4 . 1 7 7 mm (0.002 - 0.004 in)
( 0 . 1 5 7 - 0 . 1 6 4 in) Max. Allowable (Rocking Method) 0.4318 mm
Weight 582 - 586 grams (0.01 7 in)
( 2 0 . 5 3 - 2 0 . 6 7 oz) Guide Bore Diameter (Std) 9.500 - 9.525 mm
(0.374 - 0.375 in)
Piston Pins
Clearance In Piston 0.006 - 0.019 mm

(0.00023 - 0.00074 in)
Diameter 25.007 - 25.015 mm
(0.9845 - 0.9848 in)
End Play NONE
Length 67.8 - 68.3 mm
(2.67 - 2.69 in) J9509-69
(1.967 in) Closes (ATC) 23°
Spring Tension @ 41.66 mm = 378 N Opens (BBC) 61°
(Valve Closed) ( 6 1.64 in = 85 lbs) Duration ...264°

(Valve Open) (@ 1.212 in = 200 lbs) Closes (ABC) 80°
Number of Coils.......... 6.8 Opens (BTC) 13°
Installed Height 41.66 mm Duration 274°
(Spring Seat to Retainer) (1.64 in) Valve Overlap 36.5°
Wire Diameter 4.50 mm
(0.177 in)
J9509-97
OWERSIZE AND UNDERSIZE ENGINE

COMPONENT MARKINGS
CONDITION IDENTIFICATION LOCATION O F IDENTIFICATION
0.025 mm (0.001 inch) R or M Milled flat on number three crankshaft

U/S Crankshaft M-2-3 etc. (Indicating No. 2 & 3 main counterweight
bearing journal)
and/or
R-l-4 etc. (Indicating No. 1 & 4 connecting
rod journal)
0.508 mm (0.020 inch) A Following engine serial number.

O/S Cylinder Bores
0.203 mm (0.008 inch) 3/8" diamond-shaped stamp Top pad — Front

O / S Tappets • of engine and flat ground on outside surface of
each O / S tappet bore.
0.127 mm (0.005 inch) X Milled pad adjacent To two 3/8" tapped holes
O / S Valve Stems on each end of cylinder head.
J9209-120
TORQUE
Adjusting Strap Bolt 23 N«m (200 in. lbs.) Rear Mount - Support Cushion-to-
Crossmember Nut 47 N«m (35 ft. lbs.)
Camshaft Bolt 68 N*m (50 ft. lbs.) Rear Mount - Support Cushion-to-
Camshaft Thrust Plate Bolts 24 N*m (210 in. lbs.) Trans. Support Bracket Nuts 47 N«m (35 ft. lbs.)
Chain Case Cover Bolts 41 N»m (30 ft. lbs.) Rear Mount - Transmission Support
Connecting Rod Cap Bolts 61 N*m (45 ft. lbs.) Bracket Bolts 102 N®m (75 ft. lbs.)
Crankshaft Main Bearing Cap Bolts .... 115 N®m (85 ft. lbs.) Rear Support Plate-to-Transfer
Cylinder Head Bolts Case Bolts 41 N*m (30 ft. lbs.)
1 st Step 6 8 N * m ( 5 0 ft. lbs.) Rocker Arm Bolts 23 N«m (200 in. lbs.)
2nd Step 1 4 3 N T T I (105 ft. lbs.)
Cylinder Head Cover Bolts 11 N»m (95 in. lbs.) Spark Plugs 41 N®m (30 ft. lbs.)
Starter Mounting Bolts 68 N»m (50 ft. lbs.)
Exhaust Manifold-to-Cylinder
Head Bolts/Nuts 34 N»m (25 ft. lbs. Throttle Body Bolts 23 N»m (200 in. lbs.)
Torque Converter Drive Plate
68 N®m (50 ft. lbs. Bolts 31 N*m (270 in. lbs.]
Front Mount - Engine Support Transfer Case-to-lnsulator
81 N«m (60 ft. lbs. Mounting Plate Nuts 204 N*m (150 ft. lbs.)
41 N®m (30 ft. lbs. Vibration Damper Retainer

Bolt 183 N T n (135 ft. lbs.)
Intake Manifold Bolts Refer to Procedure
in Service Manual. Water Pump-to-Chain Case
Cover Bolt 41 N*m (30 ft. lbs.)
Oil Pan Bolts 23 N*m (200 in. lbs.]
Oil Pan Drain Plug 34 N»m (25 ft. lbs.)
Oil Pump Attaching Bolts 41 N*m (30 ft. lbs.)
Oil Pump Cover Bolts 11 N»m (95 in. lbs.) J9509-140
SPECIAL TOOLS
5.9L ENGINE
Engine Support Fixture C-3487-A
Oil Pressure Gauge C-3292
Valve Spring Compressor MD-998772-A

9 - 126 5.9L ENGINE — BR
Piston Ring Compressor C-385

8.0L E N G I N E
INDEX
page page
DESCRIPTION AND OPERATION OIL PUMP 150

ENGINE COMPONENTS 130 PISTON AND CONNECTING ROD ASSEMBLY . 148
ENGINE DESCRIPTION 127 ROCKER ARMS AND PUSH RODS 136
LUBRICATION SYSTEM 128 TIMING CHAIN COVER OIL SEAL (COVER NOT
SERVICE PROCEDURES REMOVED) . . . . . . . . . . . . . . . . . . . . . . . . . . 144
CRANKSHAFT S E R V I C E 132 TIMING CHAIN COVER OIL SEAL (COVER
FITTING CONNECTING ROD BEARINGS 132 REMOVED) . . . 144
FITTING CRANKSHAFT MAIN BEARINGS 132 TIMING CHAIN COVER 141
FITTING PISTONS 131 TIMING CHAIN 143
FITTING RINGS 131 VALVE STEM SEAL AND SPRING
MEASURING TIMING CHAIN S T R E T C H 130 REPLACEMENT 136
VALVE TIMING 130 VALVES AND VALVE SPRINGS . 139
REMOVAL AND INSTALLATION VIBRATION DAMPER 141
CAMSHAFT BEARING 146 DISASSEMBLY AND ASSEMBLY
CAMSHAFT 144 CYLINDER BLOCK . . . . . . . . . . . . . . . . . . 153
CRANKSHAFT MAIN BEARINGS 149 VALVE SERVICE 152
CRANKSHAFT REAR S E A L / RETAINER 150 CLEANING AND INSPECTION
CRANKSHAFT 149 CYLINDER BLOCK 155
CYLINDER HEAD C O V E R 135 CYLINDER HEADS 153
CYLINDER HEADS 137 OIL PAN 154
ENGINE ASSEMBLY 134 OIL PUMP 154
ENGINE C O R E OIL—CAMSHAFT PLUGS 151 SPECIFICATIONS
ENGINE MOUNTS—FRONT 133 8.0L ENGINE 156
ENGINE MOUNT—REAR . . 133 SPECIAL TOOLS
HYDRAULIC TAPPETS 140 8.0L ENGINE . 160
OIL PAN 147
DESCRIPTION A N D OPERATION
Engine Type.. 90° V-10OHV
Bore and Stroke 101.6 x 98.6 mm (4.00 x 3.88 in.)
ENGINE DESCRIPTION
Displacement .....8.0L (488 cu. in.)
The 8.0 Liter (488 CID) ten-cylinder engine is a
Compression Ratio 8.4:1
V-Type lightweight, single cam, overhead valve
Torque 617 N«m (450 ft. lbs.) @ 2,400 rpm
engine with hydraulic roller tappets (Fig. 1).
Firing Order 1-10-9-4-3-6-5-8-7-2
This engine is designed for unleaded fuel.
Lubrication Pressure Feed - Full Flow Filtration
Engine lubrication system consists of a gerotor
(Direct Crankshaft Driven Pump)
type oil pump mounted in the timing chain cover, and
Engine Oil Capacity 6.6L (7.0 Qts) w/filter
driven by the crankshaft. The V-10 uses a full flow
Cooling System Liquid Cooled - Forced Circulation
oil filter.
Cooling Capacity 20.5L (21.75 Qts)
Cylinder Block Cast Iron
Crankshaft Nodular Cast Iron
Cylinder Head Cast Iron
Combustion Chambers Wedge-High Swirl
Camshaft Nodular Cast Iron
Pistons Cast Aluminum Alloy
J9509-179
d e s c r i p t i o n a n d o p e r a t i o n {Continued)
The cylinders are numbered from front to rear; 1, The engine serial number is located on the lower
3, 5, 7, 9 on the left bank and 2, 4, 6, 8, 10 on the left front of the cylinder block in front of the engine
right bank. The firing order is 1-10-9-4-3-6-5-8-7-2 mount (Fig. 3). When component part replacement is
(Fig. 2). necessary, use the engine type and serial number for
reference.
REAR COIL PACK F i O N T COIL PACK
Fig. 8 Engine identification
LUBiiCATiOl SYSTEi
The lubrication system is a full flow filtration pres
sure feed type. Oil stored i n the oil pan is taken i n
and discharged by an internal gear pump directly
coupled to the crankshaft. Its pressure is regulated
by the relief valve located i n the chain case cover.
RIGHT LEFT The oil is pump through an oil filter and feeds three
RANK BANK main oil gallery. This oil gallery feeds oil under pres
FIRING ORDER sure to the main and rod bearings and camshaft
1.10.9-4-3-6-5-8-7-2 J 948D-12 bearings. Passages i n the cylinder block feed oil to
Fig. 2 Firing Order the hydraulic lifters through hollow push rods which
feeds the rocker arm sockets.
OIL GALLERY
FOR TAPPETS
CAMSHAFT
HYDRAULIC
TAPPET
CAM BEARINGS GALLERIES
FRTOF
BLOCK
OIL PICKUP J9505H44
Fig. 4 Engine Lubrication System

DESCRIPTION AMD O P E R A T I O N |C©ntinuedl
ENGINE COiPONENTS SERVICE PROCEDURES
CYLINDER HEAD COVER VALVE TIMING

Die-cast magnesium cylinder head covers reduce (1) Turn crankshaft until the No.6 exhaust valve is
noise and provide a good sealing surface. A steel closing and No.6 intake valve is opening.
backed silicon gasket is used with the cylinder head (2) Insert a 6.350 mm (1/4 inch) spacer between rocker
cover. This gasket can be used again. arm pad and 'stem tip of No.l intake valve. Allow spring
load to bleed tappet down giving in effect a solid tappet.
CYLINDER HEADS
(3) Install a dial indicator so plunger contacts
The alloy cast iron cylinder heads (Fig. 5) are held
valve spring retainer as nearly perpendicular as pos
in place by 12 bolts. The spark plugs are located i n
sible. Zero the indicator.
the peak of the wedge between the valves.
(4) Rotate the crankshaft clockwise (normal running
INTAKE VALVES INTAKE VALVES INTAKE VALVE
direction) until the valve has lifted 0.863 mm (0.034 inch).
The timing of the crankshaft should now read from 10°
before top dead center to 2° after top dead center. Use a
protractor as there are no timing marks on the engine.
CAUTION: DO NOT turn crankshaft any further

clockwise as valve spring might bottom and result
in serious damage.
(5) I f reading is not within specified limits:

(a) Check sprocket index marks.
(b) Inspect timing chain for wear.
EXHAUST EXHAUST (c) Check accuracy of TDC mark on timing indicator.
VALVES • VALVE
MEASURING TIMING CHAIN STRETCH
J9409-1
Fig. 5 Cylinder Head Assembly
WALWES AMD WALWE SPRINGS (2) Place a torque wrench and socket over camshaft
The valves are arranged in-line and inclined 18°. sprocket attaching bolt. Apply torque in the direction of
The rocker pivot support and the valve guides are crankshaft rotation to take up slack; 41 N-m (30 ft. lbs.)
cast integral with the heads. torque with cylinder head installed or 20 N-m (15 ft. lbs.)
torque with cylinder head removed. With a torque applied
PISTON AMD CONNECTING ROD ASSEMBLY to the camshaft sprocket bolt, crankshaft should not be
The pistons are elliptically turned so that the permitted to move. It may be necessary to block the crank
diameter at the pin boss is less than its diameter shaft to prevent rotation.
across the thrust face. This allows for expansion (3) Hold a scale with dimensional reading even with the
under normal operating conditions. Under operating edge of a chain link. With cylinder heads installed, apply
temperatures, expansion forces the pin bosses away 14 N-m (30 ft. lbs.) torque in the reverse direction. With
from each other, causing the piston to assume a more the cylinder heads removed, apply 20 N-m (15 ft. lbs.)
nearly round shape. torque in the reverse direction. Note the amount of chain
All pistons are machined to the same weight, movement (Fig. 6).
The piston pin rotates in the piston only and is
The pistons have a unique dry-film lubricant coat
ing baked onto the skirts to reduce friction. The
lubricant is particularly effective during engine
break-in, but with time, the material becomes embed
ded into cylinder bore walls and continues to reduce
friction.
Fig. 6 Measuring Timing Chain Wear and Stretch

(4) Install a new timing chain, i f its movement used to push the rings down to ensure positioning
exceeds 3.175 mm (1/8 inch). rings squarely in the cylinder bore before measur
ing.
FITTING PISTONS (b) Insert feeler stock in the gap. Gap for com
Piston and cylinder wall must be clean and dry. pression rings should be between 0.254-0.508 mm
Specified clearance between the piston and the cylin (0.010-0.020 inch). The oil ring gap should be
der wall is 0.013-0.038 mm (0.0005-0.0015 inch). 0.381-1.397 mm (0.015-0.055 inch).
Piston diameter should be measured at the top- of (c) Rings with insufficient end gap may be prop
skirt, 90° to piston pin axis. Cylinder bores should be erly filed to the correct dimension. Ends should be
measured halfway down the cylinder bore and trans stoned smooth after filing with Arkansas White
verse to the engine crankshaft center line. Stone. Rings with excess gaps should not be used.
Pistons and cylinder bores should be measured at (2) Install rings and confirm ring side clearance:
normal room temperature, 21°C (70°F). (a) Install oil rings being careful not to nick or
(1) To correctly select the proper size piston, a cyl scratch the piston. Install the oil control rings
inder bore gauge, capable of reading in .0001" according to instructions in the package. I t is not
INCREMENTS is required (Fig. 7). I f a bore gauge is necessary to use a tool to install the upper and
not available, do not use an inside micrometer. lower rails. Insert oil rail spacer first, then side
(2) The coating material is applied to the piston rails.
after the final piston machining process. Measuring (b) Install the second compression rings using
the outside diameter of a coated piston will not pro Installation Tool C-4184. The compression rings
vide accurate results. Therefore measuring the inside must be installed with the identification mark face
diameter of the cylinder bore with a dial Bore Gauge up (toward top of piston) and chamfer facing down.
is MANDATORY.. To correctly select the proper size An identification mark on the ring is a drill point,
piston, a cylinder bore gauge capable of reading in a stamped letter O, an oval depression or the word
.0001" increments is required. TOP (Fig. 8) (Fig. 10).
(3) Piston installation into the cylinder bore require (c) Using a ring installer, install the top com
slightly more pressure than that required for non-coated pression ring with the chamfer facing up (Fig. 10).
pistons. The bonded coating on the piston will give the An identification mark on the ring is a drill point,
appearance of a line-to-line fit with the cylinder bore. a stamped letter O, an oval depression or the word
TOP facing up.
(d) Measure side clearance between piston ring
and ring land. Clearance should be 0.074-0.097 mm
(0.0029-0.0038 inch) for the compression rings. The
steel rail oil ring should be free in groove, but
should not exceed 0.246 mm (0.0097 inch) side
clearance.
SECOND COMPRESSION RING CHAMFER

(BLACK CAST IRON)
CYLINDER
BORE
J9509-125
TWO
DOTS J9009-46
Fig. 7 Bore Gauge
Fig. 8 Second Compression Ring Identification—Typical
FITTING RINGS (3) Arrange ring gaps 180° apart as shown in (Fig.
(1) Measurement of end gaps: 11).
(a) Measure piston ring gap 2 inches from bot
tom of cylinder bore. An inverted piston can be
S - 132 8.0L E I G I I E BR
TOP COMPRESSION RING • Each bearing cap has a small V-groove across the
(GRAY IN COLOR) parting face. When installing the lower bearing shell,
make certain that the V-groove i n the shell is in line
CHAMFEP with the V-groove in the cap. This provides lubrica
tangs are in the machined grooves i n the rods and
caps.
journals should be held to 0.025 mm (0.001 inch).
Bearings are available in 0.025 mm (0.001 inch),
J 9 0 0 9 - 4 8 0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254
mm (0.010 inch) and 0.305 mm (0.012 inch) under
Fig, 9 Top Compression Ring identification—Typical size. Install the bearings in pairs. DO NOT use a
new bearing half with an old bearing half. DO
CHAMFER TOP COMPRESSION
NOT file the rods or bearing caps.
FITTING CRANKSHAFT MAIN BEARINGS

SECOND
changeable. All lower main bearing halves are inter
COMPRESSION changeable. Upper main bearing halves of No. 2, 4,
RING and 5 are interchangeable. Upper main bearing
halves of No. 1 and 6 are interchangeable, this also
CHAMFER applies to the lower bearing halves.
PISTON J9409-37
The No.3 main bearing is flanged to carry the
Fig. 10 Compression Ring Chamfer Location- crankshaft thrust loads. This bearing is NOT inter
Typical changeable with any other bearing halves in the
engine. Bearing shells are available in standard and
TOP COMPRESSION RING G A P the following undersizes: 0.25 mm (0.001 inch), 0.051
U P P E R OIL RING GAP
mm (0.002 inch), 0.076 mm (0.003 inch), 0.254 mm
(0.010 inch) and 0.305 mm (0.012 inch). Never install
an undersize bearing that will reduce clearance
below specifications.
SPACER FRONT CRANKSHAFT SERVICE

GAP OF The crankshaft connecting rod and main journals
ENGINE
should be checked for excessive wear, taper and scor
(0.012 inch) under the standard journal diameter. DO
2ND COMPRESSION RING GAP
L O W E R O I L RAIL G A P
J9409-77 NOT nick crank pin or bearing fillets. After grinding,
Fig. 11 Proper Ring Installation clean out all oil passages.
FITTING CONNECTING ROD BEARINGS
The bearing caps are not interchangeable and
assembly.
mm—-— —— 8.0L ENGINE I - 133

direction as the engine rotates.
ENGINE MOUNTS—FRONT
REMOVAL
(2) Position fan to assure clearance for radiator top
tank and hose.
CAUTION: DO NOT lift the engine by the intake
manifold.

(5) Lift the engine SLIGHTLY and remove the CUSHION
BRACKET
thru-bolt and nut and rubber engine restrictors. (Fig. J9409-54
12).
(6) Remove engine support bracket/cushion bolts Fig. 13 Positioning Engine Mounts—Front
(Fig. 12). Remove the support bracket/cushion and
(6) Remove lifting fixture.
heat shields.
ENGINE MOUNT—REAR
REMOVAL
(1) Raise the vehicle on a hoist.
(2) Position a transmission jack in place.
(3) Remove support cushion stud nuts (Fig. 14).
(4) Raise rear of transmission and engine
SLIGHTLY.
port cushion.
(6) If necessary, remove the bolts holding the
RESTRICTION PADS
J9409-144 INSTALLATION
(1) If removed, position the transmission support
Fig. 12 Engine Mounts—Front bracket to the transmission. Install new attaching
INSTALLATION (2) Position support cushion to transmission sup
(1) With engine raised SLIGHTLY, position the port bracket. Install stud nuts and tighten to 47 N-m
engine support bracket/cushion and heat shields to (35 ft. lbs.) torque.
the block. Install new bolts and tighten to 81 N-m (60 (3) Using the transmission jack, lower the trans
ft. lbs.) torque. mission and support cushion onto the crossmember
(2) Install the thru-bolt and 2 piece rubber engine (Fig. 14).
rubber restrictors onto the engine support bracket/ (4) Install the support cushion bolts and tighten to
cushion. 47 N-m (35 ft. lbs.) torque.
(3) Lower engine with support/lifting fixture while (5) Remove the transmission jack.
guiding the engine bracket/cushion and thru-bolt into (6) Lower the vehicle.
support cushion brackets (Fig. 13).
(4) Install thru-bolt nuts and tighten the nuts to
S - 134 8.0L ENGINE BR
J9509-126
Fig. 14 Engine Rear Support Cushion Assembly

ENGINE ASSEMBLY (17) Remove the air cleaner.
(18) Disconnect the throttle linkage.
REMOVAL (19) Remove throttle body.
(1) Remove the battery. (20) Remove the upper intake manifold (refer. to
(2) Drain cooling system (refer to Group 7, Cooling Group 11, Exhaust System and Intake Manifold).
System for the proper procedure). (21) Remove the coil assemblies with the ignition
(3) Discharge the air conditioning system, i f cables.
equipped (refer to Group 24, Heating and Air Condi (22) Disconnect the heater hoses.
tioning for service procedures). (23) Disconnect the power steering hoses, i f
(4) Remove the upper crossmember. equipped.
(5) Remove the transmission oil cooler. (24) Perform the Fuel System Pressure release
(6) Remove the serpentine belt (refer to Group 7, procedure (refer to Group 14, Fuel System). Discon
Cooling System). nect the fuel line.
(7) Remove the A/C compressor with the lines (25) On Manual Transmission vehicles, remove the
attached. Set aside. shift lever (refer to Group 21, Transmissions).
(8) I f equipped, remove the condenser. (26) Raise and support the vehicle on a hoist.
(9) Remove the washer bottle. (27) Remove the drain plug and drain the engine
(10) Disconnect the top radiator hose. oil
(11) Remove the fan. (28) Loosen front engine mount thru-bolt nuts.
(12) Remove the fan shroud. (29) Remove the transmission cooler line brackets
(13) Disconnect the lower radiator hose. from oil pan.
(14) Disconnect the transmission cooler lines. (30) Disconnect exhaust pipe at manifold (refer to
(15) Remove radiator (refer to Group 7, Cooling Group 11, Exhaust System and Intake Manifold).
System). (31) Disconnect the starter wires. Remove starter
(16) Remove the generator with the wire connec motor (refer to Group 8B, Battery/Starter/Generator
tions (refer to Group 8B, Battery/Starter/Generator Service).
Service).
mm - • 8.0L ENGINE S - 135
(32) Refer to Group 21, Transmissions for trans (25) Connect the lower radiator hose.
mission removal. (26) Install the transmission oil cooler.
(33) Lower vehicle. (27) Connect the transmission cooler lines.
CAUTION: DO NOT lift the engine by the intake (29) Install the fan shroud.
manifold. (30) Install the fan.
(31) Connect the top radiator hose.
(34) Install an engine lifting fixture. (32) Install the washer bottle.
(35) Remove engine from vehicle and install (33) I f equipped, install the condenser.
engine assembly on a repair stand. (34) Install the A/C compressor with the lines
attached.
INSTALLATION
Cooling System).
tion In the engine compartment. Position the thru-
(36) Evacuate and charge the air conditioning sys
bolt into the support cushion brackets.
tem, i f equipped (refer to Group 24, Heating and Air
Conditioning for service procedures).
(37) Add coolant to the cooling system (refer to
Group 7, Cooling System for the proper procedure).
sion installation.
(38) Install the battery.
(5) Install the prop shaft (refer to Group 16, Pro
(39) Warm engine and adjust.
peller Shaft).
(6) Install the starter and connect the starter
wires (refer to Group 8B, Battery/Starter/Generator
CYLINDER HEAD COVER
Service).
Die-cast magnesium cylinder head covers (Fig. 15)
(7) Install exhaust pipe to manifold (refer to Group
reduce noise and provide a good sealing surface. A
11, Exhaust System and Intake Manifold).
steel backed silicon gasket is used with the cylinder
(8) Install the transmission cooler line brackets
head cover (Fig. 16).
from oil pan.
(9) Tighten the Front mount thru-bolts and nuts to
102N*m (75 ft. lbs.).
(11) Prime oil pump by squirting oil in the oil filter
mounting hole and filling the J-trap of the front tim
ing cover. When oil is running out, install oil filter
that has been filled with oil.
(13) Remove engine lifting fixture.
(14) On Manual Transmission vehicles, install the
shift lever (refer to Group 21, Transmissions).
(15) Connect the fuel lines.
(17) Install the upper intake manifold (refer to
Group 11, Exhaust System and Intake Manifold).
(18) Install the coil assemblies with the ignition
cables.
(19) Using a new gasket, install throttle body.
Tighten the throttle body nuts to 23 N-m (200 in.
lbs.) torque.
(20) Connect the throttle linkage.
(21) Install the air cleaner box.
(22) Install the generator and wire connections
(refer to Group 8B, Battery/Starter/Generator Ser
vice).
(23) Install the upper crossmember.
(24) Install radiator (refer to Group 7, Cooling Sys
tem). Fig. 15 Cylinder Head Covers
9 • 136 8.0L ENGINE
REMOVAL A N D I N S T A L L A T I O N (Continued)
CYLINDER HEAD COVER GASKETS LEFT (3) Remove the rocker arm bolts and the rocker
arm assembly (Fig. 17). Place rocker arm assemblies
on a bench in the same order as removed.
(4) Remove the push rods and place them on a
bench in the same order as removed.
ROCKER
• ARM
PEDESTALS
Fig. 16 Cylinder Head Cover Gaskets

REMOVAL
(2) Disconnect closed ventilation system and evap
oration control system from cylinder head cover.
Identify each system for installation.
(3) Remove the upper intake manifold to remove
the right side head cover (refer to Group 11, Exhaust
System and Intake Manifold). J9409-60
(4) Remove cylinder head cover bolts and stud
bolts. Remove the covers and gaskets. The gasket Fig. 17 Rocker Arm Assembly
may be used again. INSTALLATION
INSTALLATION CAUTION: DO NOT rotate or crank the engine dur
(1) Clean cylinder head cover gasket surface. ing or immediately after rocker arm installation.
(2) Clean head rail, i f necessary. Allow the hydraulic roller tappets adequate time to
(3) Check the gasket for use in head cover instal bleed down (about 5 minutes).
lation. I f damaged, use a new gasket.
(4) Install the gasket onto the head rail. For the (1) Install the push rods i n the same order as
left side the number tab is at the front of removed.
engine with the number up. For the right side (2) Install rocker arm assemblies i n the same
the number tab is at the rear of engine with the order as removed. Tighten the rocker arm bolts to 28
number up, N-m (21 ft. lbs.) torque.
(3) Install cylinder head cover and gasket. DO
CAUTION: The cylinder head cover fasteners have NOT use alternative fasteners.
a special plating. DO NOT use alternative fasteners. (4) Connect spark plug wires.
ket. Install the stud bolts and hex head bolts in the VALVE STEM SEAL AND SPRING REPLACEMENT
proper positions (Fig. 15). Tighten the stud bolts and This procedure is done with the cylinder head
the bolts to 16 N-m (144 in. lbs.) torque. installed.
(6) I f removed, install the upper intake manifold (1) Disconnect the negative cable from the battery.
(refer to Group 11, Exhaust System and Intake Man (2) Set engine basic timing to Top Dead Center
ifold). (TDC) and remove air cleaner.
(7) Install closed crankcase ventilation system and (3) Remove cylinder head covers and spark plugs.
evaporation control system onto the proper head (4) Using suitable socket and flex handle at crank
cover. DO NOT switch the systems. shaft retaining bolt, turn engine so the No.l piston is
(8) Connect the negative cable to the battery. at TDC on the compression stroke.
ROCKER ARMS AND PUSH RODS (6) With air hose attached to an adapter installed
in N o . l spark plug hole, apply 620-689 kPa (90-100
REMOVAL
psi) air pressure.
(1) Disconnect spark plug wires by pulling the boot
(7) Using Valve Spring Compressor Tool
straight out in line with plug.
MD-998772A with adapter 6716A, compress valve
(2) Remove cylinder head cover and gasket.
spring and remove retainer valve locks and valve
spring.
BR
(8) Install seals on the exhaust valve stem and
position down against valve guides. The exhaust
valve stem seal is brown.
(9) The black Intake valve stem seals should be
pushed firmly and squarely over the valve guide
using the valve stem as a guide. DO NOT force seal
against top of guide. When installing the valve
retainer locks, compress the spring only enough to
install the locks.
(10) Follow the same procedure on the remaining 9
cylinders using the firing sequence 1-10-9-4-3-6-5-8-
7-2. Make sure piston i n cylinder is at TDC on the
valve spring that is being removed.
hole.
again. Install the gasket onto the head rail. F o r the
left side the number tab is at the front of
engine with the number up. For the right side
the number tab is at the rear of engine with the
number up.
CAUTION" The cylinder head cover fasteners have

a special plating. DO NOT use alternative fasteners.
ket. Install the stud bolts and hex head bolts i n the
proper positions (Fig. 18). Tighten the stud bolts and
the bolts to 16 N-m (144 in. lbs.) torque.
(15) Install closed crankcase ventilation system. Fig. 18 Cylinder Head Covers
(16) Connect the evaporation control system.
(19) Road test vehicle and check for leaks.
CYLINDER HEADS
REMOVAL
(3) Remove the heat shields (Fig. 19).
, (5) Remove closed crankcase ventilation system.
(6) Disconnect the evaporation control system.
(7) Remove the air cleaner. Fig. 19 Spark Plug Wire Heat Shields (Left Side
(8) Perform the Fuel System Pressure release pro Shown)
cedure (refer to Group 14, Fuel System). Disconnect
the fuel line. (14) Remove upper intake manifold and throttle
(9) Disconnect accelerator linkage and i f so body as an assembly.
equipped, the speed control and transmission kick- (15) Remove cylinder head covers and gaskets.
down cables. (16) Remove the EGR tube. Discard the gasket, for
(10) Remove coil pack and bracket (Fig. 20). right side only.
(11) Disconnect the coil wires. (17) Remove lower intake manifold. Discard the
(12) Disconnect heat indicator sending unit wire. flange side gaskets and the front and rear cross-over
(13) Disconnect heater hoses and bypass hose. gaskets.
9 - 138 8.QL ENGINE

COIL PACKS
A N D BRACKET
J9409-14
MOUNTING Fig. 21 Cylinder Head Bolt Tightening Sequence

BOLTS (4)
(5) Install the side intake manifold gaskets. Be
sure that the locator dowels are positioned in the
head (Fig. 22).
F I O N T OF ENGINE J9414-55
Fig, 20 Coii Pack and Bracket

(18) Disconnect exhaust pipe from exhaust mani
fold (refer to Group 11, Exhaust System and Intake
Manifold).
(19) Remove exhaust manifolds and gaskets (refer
to Group 11, Exhaust System and Intake Manifold). Fig. 22 Intake Manifold Flange Gasket Alignment
(20) Remove rocker arm assemblies and push rods.
(6) Peel off the protective paper (blue - rear and
Identify to ensure installation in original locations.
brown - front) and press firmly onto the block (Fig.
(21) Remove the head bolts from each cylinder
head and remove cylinder heads. Discard the cylin 23). BE SURE T H E BLOCK IS O I L FREE*Align-
der head gasket. ing slots in end seals with notches in intake manifold
(22) Remove spark plugs. gaskets.
INSTALLATION
(1) Position the new cylinder head gaskets onto
the cylinder block.
(2) Position the cylinder heads onto head gaskets
and cylinder block.
(3) Tighten the cylinder head bolts in two steps
(Fig. 21):
• Step 1—Tighten all cylinder head bolts, i n
sequence, to 58 N-m (43 ft. lbs.) torque.
• Step 2—Tighten all cylinder head bolts, i n
sequence, to 143 N-m (105 ft. lbs.) torque.
CAUTION: When tightening the rocker arm bolts,

make sure the piston in that cylinder is NOT at
(BLUE PEEL-OFF) J9409-63
TDC. Contact between the valves and piston could
occur. Fig. 23 Intake Manifold-to-Block Seals
(4) Install push rods and rocker arm assemblies i n (7) Insert Mopar® Silicone Rubber Adhesive Seal
their original position. Tighten the bolts to 28 N-m ant, or equivalent, into the four corner pockets (Fig.
(21 ft. lbs.) torque. 24). F i l l the pocket, but DO NOT overfill.
(18) Install coil packs and bracket. Tighten the
bracket bolts to 21 N-m (190 in. lbs.) torque. Connect
the coil wires.
(19) Connect heat indicator sending unit wire.
(20) Connect the heater hoses and bypass hose.
(21) Connect the accelerator linkage and i f so
down cables.
(22) Install the fuel line.
(23) Install the generator and drive belt. Tighten
torque. Tighten the adjusting strap bolt to 23 N-m
tem for adjusting the belt tension.
(24) Install the intake manifold-to-generator
bracket support rod. Tighten the bolts to 41 N-m (30
ft. lbs.) torque.
again. Install the gasket onto the head rail. For the
left side the number tab is at the front of
engine with the number up. For the right side
the number tab is at the rear of engine with the
Fig. 24 Mopar® Silicone Rubber Adhesive Sealant number up.
Application Locations
CAUTION: The cylinder head cover fasteners have
(8) The lower intake manifold MUST be installed a special plating. DO NOT use alternative fasteners.
within 3 minutes of sealant application. Carefully (26) Position the cylinder head cover onto the gas
lower intake manifold into position on the cylinder ket. Install the stud bolts and hex head bolts in the
block and cylinder heads. After intake manifold is in proper positions (Fig. 1). Tighten the stud bolts and
place, inspect to make sure seals and gaskets are i n the bolts to 16 N-m (144 in. lbs.) torque.
place. (27) Install closed crankcase ventilation system.
(9) Finger start all bolts, alternate one side to the (28) Connect the evaporation control system.
other. (29) Install the air cleaner.
(10) Tighten the lower intake manifold bolts to 54 (30) Fill cooling system (refer to Group 7, Cooling
N-m (40 ft. lbs.) torque. System for proper procedure).
(11) Using a new gasket, position the upper intake (31) Connect the negative cable to the battery.
manifold onto the lower intake manifold. (32) Check for leaks (fuel, oil, antifreeze, etc.).
(12) Tighten upper intake manifold bolts to 22
N-m (16 ft. lbs.) torque. VALVES ANi VALVE SPRINGS
(13) Install the exhaust manifolds and new gas
kets. Tighten the bolts and stud bolts to 22 N-m (16 REMOVAL
ft. lbs.) torque. (1) Remove the cylinder head.
(14) Install exhaust pipe to the exhaust manifold. (2) Special studs must be used to adapt the Valve
Tighten the bolts to 34 n-m (25 ft. lbs.) torque. Spring Compressor Tool to the V-10 cylinder head
(15) Using a new gasket, position the EGR tube to (Fig. 25). Install the metric end into the Special Tool
the intake manifold and the exhaust manifold. MD998772A and the 5/16 end into the cylinder head.
Tighten the EGR tube nut to 34 N-m (25 ft. lbs.) (3) Compress valve springs using Valve Spring
torque. Tighten the bolts to 20 N-m (174 in. lbs.) Compressor Tool MD-998772A with Adapter 6716A
torque. and Screw 6765 (Fig. 26). Tap the retainer using a
(16) Install the heat shields and the washers. brass drift and ball peen hammer to loosen locks
Make sure that heat shields tabs hook over the away from retainer.
exhaust gasket. Tighten the nuts to 15 N-m (132 in. (4) Remove valve retaining locks, valve spring
lbs.) torque. retainers and valve springs. Check for abnormal
(17) Adjust spark plugs to specifications (refer to wear, replace as required.
Group 8D, Ignition System). Install the plugs and (5) Remove the valve stem seals.
tighten to 41 N-m (30 ft. lbs.) torque. (6) Before removing valves, remove any burrs from
valve stem lock grooves to prevent damage to the
I - 140 8J L EliSlE
R E M O V A L AMB I N S T A L L A T I O N fContinued)
(6) Install new seals on all valve guides (BLACK
FITS INTO TOOL MD 998772A
on intake and BROWN on exhaust). Install valve
springs and valve retainers.
(7) Compress valve springs with Valve Spring
Compressor Tool MD-998772A and adapter 6716A,
install locks and release tool. Tap the retainer with a
brass or heavy plastic hammer to ensure locks have
been seated.
(8) I f valves and/or seats were ground, measure
the installed height of springs. Make sure the mea
surement Is taken from bottom of spring seat in cyl
inder head to the bottom surface of spring retainer. I f
spacers are installed, measure from the top of spacer.
I f height is greater than 42.86 mm (1-11/16 inches),
install a 1.587 mm (1/16 inch) spacer in head coun-
terbore. Ensure this brings spring height back to nor
mal, 41.27 to 42.86 mm (1-5/8 to 1-11/16 inch).
HYDRAULIC TAPPETS
FITS INTO CYLINDER HEAD REMOVAL

J9409-95 (1) Disconnect the negative cable from the battery.
Fig. 25 Special Studs 6715 for ¥-10 Engine
(3) Remove cylinder head cover.
(4) Remove rocker arm assembly and push rods.
Identify push rods to ensure installation in original
location.
(5) Remove upper and lower intake manifold.
(6) Cut the cylinder head gasket for accessibility i f
the end tappets are to be removed.
(7) Remove yoke retainer spider and tappet align
ing yokes (Fig. 27).
Fig. 26 Vaive Spring Compressor MD-998772A with

Adaptor 6716-A and Screw 6765
valve guides. Identify valves to ensure Installation in
original location.
INSTALLATION
(1) Clean valves thoroughly. Discard burned,
warped and cracked valves.
(2) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
(3) Measure valve stems for wear. I f wear exceeds
0.051 mm (0.002 inch), replace the valve.
(4) Make sure there are no burrs on valve stems.
(5) Coat valve stems with lubrication oil. Insert
valves into valve guides in cylinder head. Fig, 27 Tappets, Aligning Yoke and Yoke Retaining
Spider

(8) Pull tappet out of bore with a twisting motion.
If all tappets are to be removed, identify tappets to
ensure installation in original location.
(9) i f the tappet or bore in cylinder block is scored,
scuffed, or shows signs of sticking, ream the bore to
(10) Check camshaft lobes for abnormal wear.
INSTALLATION
(1) Lubricate tappets.
(2) Install tappets in their original positions.
Ensure that the o i l bleed hole ( i f so equipped)
faces forward.
(3) install tappet aligning yokes. Position the yoke
retainer spider over the tappet aligning yokes (Fig.
27) Install the yoke retaining spider bolts and
(4) Install the push rods In their original location.
(5) Position the rocker arm assembly on the pedes
tal and align to the push rods. Install the bolts and
J9409-138
(6) Install lower and upper intake manifold.
Fig. 28 Crankshaft Pulley—Damper
left side the number tab is at the front of INSTALLATION
engine w i t h the number up. F o r the r i g h t side (1) Position the crankshaft pulley/damper onto the
the number tab is at the rear of engine with the crankshaft.
number up. (2) Use tool C-3688 to press the pulley/damper
(8) Position the cylinder head cover onto the gas onto the crankshaft. Install crankshaft bolt and
ket. Install the stud bolts and hex head bolts in the washer and tighten to 183 N-m (135 ft. lbs.) torque
proper positions (Fig. 27). Tighten the stud bolts and (Fig. 29).
the bolts to 16 N-m (144 in. lbs.) torque. (3) Install the serpentine belt (refer to Group 7,
(9) Install the air cleaner. Cooling System).
CAUTION: To prevent damage to valve mechanism, bolts to 23 N-m (17 ft. lbs.) torque.
engine must not be r u n above fast idle until all (5) Position the fan shroud and install the bolts.
hydraulic tappets have filled with oil and have Tighten the bolts to 11 N-m (95 in. lbs.) torque.
become quiet. (6) Connect the negative cable to the battery.
(10) Connect the negative cable to the battery. THING CHAIN COWEi
REMOVAL
fiBFtATION i A i P E i (1) Disconnect the negative cable from the battery.
REMOVAL System).
(1) Disconnect the negative cable from the battery (3) Remove the serpentine belt (refer to Group 7,
(2) Remove fan shroud retainer bolts and set Cooling System).
shroud back over engine. (4) Remove fan shroud.
(3) Remove the cooling system fan. (5) Remove fan.
(4) Remove the serpentine belt (refer to Group 7, (6) Unbolt A/C compressor and set on top of
Cooling System). engine.
(5) Remove crankshaft pulley/damper bolt and (7) Remove generator, air pump, and bracket
washer from end of crankshaft (Fig. 28). assembly.
(6) Using a 3-prong puller tool, pull pulley— (8) Remove water pump (refer to Group 7, Cooling
damper off of the crankshaft. System).
(7) Inspect crankshaft oil seal (Fig. 29). (9) Using a 3-prong puller to remove pulley/
damper from the crankshaft. (Fig. 30)
INSTALLATION
(1) Be sure mating surfaces of timing chain cover
(2) Lubricate the pump rotors using petroleum
jelly or lubriplate and install in the timing chain
cover (Fig. 31).
J9409-1
Fig, 29 installing Crankshaft Pulley—Damper
Fig. 31 Priming Oil Pump.

(3) Using a new cover gasket, carefully install tim
ing chain cover to avoid damaging oil pan gasket.
Use a small amount of Mopar® Silicone Rubber Adhe
sive Sealant, or equivalent, at the joint between tim
ing chain cover gasket and the oil pan gasket. Finger
(4) Tighten timing chain cover bolts to 47 N-m (35
ft. lbs.) torque. Tighten oil pan bolts to 24 N-m (215
in. lbs.) torque.
(5) Install pulley/vibration damper use tool C-3688
(Fig. 32)
(6) Prime oil pump by squirt oil in the oil filter
J9409-138 that has been filled with oil.
(7) Install water pump and housing assembly
Fig. 30 Pulley—Damper Removal using o-ring (refer to Group 7, Cooling System).
Tighten bolts to 41 N-m (30 ft. lbs.) torque.
(10) Loosen oil pan bolts and remove the front oil
(8) Install generator, air pump, and bracket assem
pan bolts that mount the pan to the timing chain
bly.
cover.
(9) Install A/C compressor.
(10) (10) Install the cooling system fan. Tighten
(12) Remove timing chain cover and gasket using
the bolts to 23 N-m (17 ft. lbs.) torque.
(11) Position the fan shroud and install the bolts.
(13) Inspect surface of cover. Remove any burrs or
Tighten the bolts to 11 N-m (95 in. lbs.) torque.
high spots.
Cooling System).
REHOI mom |C©ntinu©i)
SPECIAL
TOOL
C-3688
SPECIAL
TOOL
SPECIAL 6444
TOOL
6820
J9409-142 J9409-139
Fig. 32 installing Crankshaft Pulley/Damper Fig. 33 Crankshaft Sprocket Removal.

TIMING CHAIN
REMOVAL
(1) Remove timing chain cover and gasket using
(2) Aline camshaft and crankshaft centerline.
Remove camshaft sprocket attaching bolt and remove
timing chain and camshaft sprockets.
(3) Use puller 6444 and jaws 6820 to remove
crankshaft sprocket (Fig. 33).
INSTALLATION
(1) Line up key in crankshaft with keyway in
sprocket, press on crankshaft timing sprocket, use
tools C-3688, C-3718 and MB-990799, seat sprocket SPECIAL SPECIAL
against crankshaft shoulder (Fig. 34). TOOL TOOL
J9409-140
(.2) Turn crankshaft to line up the timing mark MD990799 C-3718
with the crankshaft and camshaft centerline.
Fig. 34 Crankshaft Sprocket Installation
(3) Put chain on camshaft sprocket.
(4) Take chain and camshaft sprocket, align timing thrust plate and up to 0.254 mm (0.010 inch) with a
marks and install chain and cam sprocket onto used thrust plate. I f not within these limits install a
crankshaft sprocket. Check to see that timing marks new thrust plate.
are on the centerline of the crankshaft and camshaft (7) Install timing chain cover. -
centerline (Fig. 35).
(5) install the camshaft bolt. Tighten the bolt to 61
9 - 144 8.QL ENGINE BR
REMOVAL AMB INSTALLATION fContinued!
CAMSHAFT
SPROCKET
TIMING
MARKS
SPECIAL
CRANKSHAFT
TOOL
SPROCKET
C-3688
J9409-69
TIMING CHAIN COVER OIL SEAL (COVER NOT

REMOVED) SPECIAL
TOOL
6806 J9409-136
REMOVAL
(1) Disconnect the negative cable from the battery. Fig. 37 Timing Chain Cover and Oil Seal
(2) Remove the cooling fan and shroud.
(3) Remove the serpentine belt (refer to Group 7, (3) Install serpentine belt (refer to Group 7, Cool
Cooling Systems). ing System).
(4) Using a 3-jaw puller tool, pull pulley/damper (4) Install cooling fan and shroud.
off of the crankshaft. ( 5 ) Connect negative cable to the battery.
seal to pry the oil seal outward. Be careful not to TIMING CHAIN COVER OIL SEAL (COVER
damage the crankshaft seal surface of the cover (Fig. REMOVED)
36).
REMOVAL
(1) With timing cover removed from engine place a
TIMING CHAIN suitable tool behind the lips of the oil seal to pry the
COVER oil seal outward. Be careful not to damage the crank
shaft seal surface of the cover.
INSTALLATION
(1) Position the crankshaft front oil seal onto seal
installer special tool 6806.
(2) Use tool 6761 to support timing chain cover
when installing oil seal with tool 6806 (Fig. 38),
install seal.
CAMSHAFT
The camshaft has an integral oil pump and distrib
J9409-68 utor drive gear (Fig. 40).
Fig. 36 Timing Chain Cover and Oil Seal REMOVAL

INSTALLATION
. (2) Remove rocker arm assemblies, identify each
(1) Position the crankshaft front oil seal onto seal
part so it can be installed in its original location..
installer special tool 6806 and C-3688 (Fig. 37).
Install seal.
part so i t can be installed in its original location.
(2) Install crankshaft pulley/damper using tool
C-3688.
BR 8.0L ENGINE I - 145
J9309-71
Fig, 40 Camshaft and Sprocket Assembly
J9409-137
Fig. 38 Oii Seal, Tools—6806 and 6761

SPECIAL .Fig. 41 Camshaft
TOOL
cam lobes.
INSTALLATION
(1) Lubricate camshaft lobes and camshaft bearing
journals. Using a long bolt, Insert the camshaft into
the cylinder block.
NOTE; Whenever an engine has been rebuilt, a new

camshaft and/or new tappets installed, add 1 pint of
Mopar® Crankcase Conditioner, or equivalent. The
oil mixture should be left in engine for a minimum
of 8 0 5 km (500 miles). Drain at the next normal oil
change.
(2) Install camshaft thrust plate. Tighten the torx

SPECIAL be 0.051-0.152 mm (0.002-0.006 inch) with a new
TOOL thrust plate and up to 0.254 mm (0.010 inch) with a
J9409-143
6 7 6 l
Fig. 39 Oil Seal installed . new thrust plate.
(4) Line up key with keyway in sprocket, press on
(4) The 4 corner tappets can not be removed with crankshaft timing sprocket, use tools C-3688, C-3718
out removing the cylinder heads and gaskets. They and MB990799, to seat sprocket against crankshaft
can be lifted and retained for camshaft removal. shoulder (Fig. 42).
(5) Remove upper and lower intake manifold (refer (5) Align timing mark on crankshaft sprocket with
to Group 11 Intake and Exhaust Systems). center line of crankshaft and camshaft.
(6) Remove timing chain cover and timing chain. (6) Put chain on camshaft sprocket.
(7) Remove camshaft thrust plate (Fig. 41). (7) Take chain and camshaft sprocket and align
(8) Install a long bolt into front of camshaft to mark with centerline of crankshaft and camshaft
facilitate removal of the camshaft. Remove camshaft, install camshaft sprocket and chain to camshaft.
SPECIAL SPECIAL
TOOL TOOL 1 Q , A o y n
J y 4 u y 1 4 U
MD990799 C-3718 "
Fig. 42 Crankshaft Sprocket Installation

(8) Install the camshaft bolt. Tighten bolt to 75
(9) Install the timing chain cover.
(10) Install the crankshaft pulley/damper use tool
C-3688.
(11) Prime oil pump by squirt oil in the oil filter Fig. 43 Cylinder Head Cower
CAMSHAFT BEARING
ing cover. When oil is running out, Install oil filter
that has been filled with oil. REMOVAL
(12) Each tappet reused must be installed in the This procedure requires that the engine is removed
same position from which i t was removed. When from the vehicle.
camshaft is replaced, a l l of the tappets must be (1) With engine completely disassembled, drive out
replaced. rear cam bearing core hole plug.
(13) Install tappets and push rods in their original (2) Install proper size adapters and horseshoe
location. washers (part of Camshaft Bearing Remover/Installer
(14) Install the rocker arms. Tool C-3132-A) at back of each bearing shell. Drive
(15) The cylinder head cover gasket can be used out bearing shells (Fig. 44).
left side the number tab is at the front of INSTALLATION
engine w i t h the number up. For the r i g h t side (1) Install new camshaft bearings with Camshaft
the number tab is at the rear of engine w i t h the Bearing Remover/Installer Tool C-3132-A by sliding
number up. the new camshaft bearing shell over proper adapter.
(2) Position rear bearing in the tool. Install horse
CAUTION: The cylinder head cower fasteners have shoe lock and by reversing removal procedure, care
a special plating. DO NOT use alternative fasteners. fully drive bearing shell into place.
(16) Position the cylinder head cover onto the gas (3) Install remaining bearings in the same man
ket, install the stud bolts and hex head bolts in the ner. Bearings must be carefully aligned to bring oil
proper positions (Fig. 43). Tighten the stud bolts and holes into full register with' oil passages from the
the bolts to 16 N-m (144 In. lbs.) torque. main bearing. If the camshaft bearing shell oil holes
(17) Install the intake manifolds, (refer to Group are not i n exact alignment, remove and install them
11 Intake and Exhaust Systems). correctly. Install a new core hole plug at the rear of
camshaft. Be sure this p l u g does not leak.
BR B.OL ENGINE 9 - 147

imSTMLLMTION
(1) Fabricate 4 alignment dowels from 5/16 x 1 1/2
inch bolts. Cut the head off the bolts and cut a slot
into the top of the dowel. This will allow easier
installation and removal with a screwdriver (Fig. 46).
1
5 / 1 6 " x l / " BOLT
2
DOWEL
AE
SLOT J9509-163

(2) Install the dowels in the cylinder block at the
SPECIAL SPECIAL four corners.
TOOL TOOL (3) Apply small amount of Mopar® Silicone Rubber
J9409-140
MD990799 C-3718
Adhesive Sealant, or equivalent at the split lines.
Fig. 44 Camshaft Bearings Removal and Installation The split lines are between the cylinder block, the
with Tool C-3132-A timing chain cover and the rear crankshaft seal
assembly (Fig. 45). After the sealant is applied
OIL PAN you have 3 minutes to install the gasket and oil
pan.
REMOVAL (4) Slide the one-piece gasket over the dowels and
(1) Disconnect the negative cable from the battery. onto the block.
(2) Raise vehicle. (5) Position the oil pan over the dowels and onto
(3) Drain engine oil. the gasket. The engine may have to be slightly raised
(4) Remove left engine to transmission strut. on 2WD vehicles.
(5) Remove oil pan and one-piece gasket. The (6) Install the oil pan bolts (Fig. 47). Tighten the
engine may have to be raised slightly on 2WD vehi 1/4 inch bolts to 11 N-m (96 in. lbs.) torque. Tighten
cles. the stud bolts to 16 N-m (144 in. lbs.) torque. Tighten
(6) Remove the oil pick-up tube assembly (Fig. 45). the 5/16 inch bolts to 16 N-m (144 in. lbs.) torque.
Discard the gasket.
PICK-UP
TUBE
SEALANT AT
SPLIT-LINE SEALANT
AT SPLIT-
LINES • 1 / 4 - 2 0 BOLTS
O 5/16-18 BOLTS J9409-74
Fig. 47 Oil Pan Bolt Location

(7) Remove the dowels. Install the remaining 5/16
inch oil pan bolts. Tighten these bolts to 16 N-m (144
J9409-76 in. lbs.) torque.
(8) Install the drain plug. Tighten drain plug to 34
Fig. 45 Oil Pick-Up Tube N-m (25 ft. lbs.) torque.
(10) Lower vehicle.
(11) Connect the negative cable to the battery. TOP COMPRESSION RING GAP
(12) Fill crankcase with oil to proper level. UPPER OIL RING GAP
PISTON AND C0NNECT1N0 iOD ASSEMBLY t if /

REMOVAL
(1) Remove the engine from the vehicle (refer to
Engine Removal of this manual). SPACER
GAP
(2) Remove the valve cover, rocker arms, push rods
and cylinder head. Mark parts as removed.
(3) Remove the oil pan and oil pump pick-up tube.
(4) Remove top ridge of cylinder bores with a reli
able ridge reamer before removing pistons from cyl
inder block. Be sure to keep tops of pistons covered
during this operation. 2ND COMPRESSION RING GAP
LOWER OIL RAIL GAP J9409-77
(5) Be sure the connecting rod and connecting rod
cap are identified with the cylinder number. Remove
Fig. 48 Proper Ring instailation
connecting rod cap. Install connecting rod bolt guide
set on connecting rod bolts. FRONT I.D.
(6) Pistons and connecting rods must be removed TOWARDS THIS SIDE
from top of cylinder block. When removing piston and
connecting rod assemblies, rotate crankshaft center
the connecting rod in the cylinder bore and at BDC.
Be careful not to n i c k crankshaft journals* DO
MOT t r y to remove black coating on s k i r t ; This
is the dry film lubricant.
ing rod.
INSTALLATION
(1) Check the crankshaft connecting rod journal
for excessive wear, taper and scoring.
(2) Check the cylinder block bore for out-of-round,
taper, scoring and scuffing.
(3) Be sure that compression ring gaps are stag
gered so that neither is in line with oil ring rail gap.
(4) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located properly (Fig. 48).
ORIENTATION BUTTON ORIENTATION BUTTON
(5) Immerse the piston head and rings in clean TOWARDS FRONT TOWARDS REAR
engine oil. Slide Piston Ring Compressor Tool C-385 (L.H. ONLY) (R.H. ONLY)
over the piston and tighten with the special wrench 1,3,5,7,9 2, 4, 6, 8, 10
(part of Tool C-385). Be sure position of rings
does not change during this operation.
(6) Install connecting rod bolt protectors on rod
J9409-78
bolts, a long protector should be installed on the
numbered side of the connecting rod.
Fig. 49 Piston and Rod Orientation
(7) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore in the chamfer of the connecting rod bore must be installed
bottom dead center position. Be sure connecting rod toward crankshaft journal fillet.
and cylinder bore number are the same. Insert rod (9) While tapping the piston down in cylinder bore
and piston into cylinder bore. Be sure the piston and with the handle of a hammer, guide the connecting
rod assemblies are installed in the proper orientation rod over the crankshaft journal.
(Fig. 49). (10) Install rod caps. Install nuts on cleaned and
(8) The notch, groove or arrow on top of piston oiled rod bolts and tighten nuts to 61 N-m (45 ft. lbs.)
must be pointing toward front of engine. The larger torque.
(11) Install the oil pump pick-up tube and oil pan.
8.0L ENGINE I - 14S
R E M O V A L AM® I N S T A L L A T I O N ( C o n t i n u e d )
(12) Install the cylinder head, push rods, rocker (4) Apply a rearward axial load of 667 N (150
arms and valve cover. Ibs-f) on crankshaft centerline, driving No.3 main cap
(18) Install lower intake manifold. and thrust bearing against No.3 bulkhead. Repeat
(14) Install the engine into the vehicle.(refer to procedure, driving crankshaft forward to align rear
Engine Installation of this manual). flange of thrust bearings i n a common plane. Front
face of No.l main cap must not extend forward i n
CRANKSHAFT IAIN BEARINGS front of face of No.l bulkhead.
(5) Install the oil pump pick-up tube and oil pan.
REMOVAL
(1) Remove the oil pan and oil pump pick-up tube. CRANKSHAFT
(2) Identify bearing caps before removal. Remove When a crankshaft is replaced, all main and con
bearing caps one at a time. necting rod bearings should be replaced with new
(3) Remove upper half of bearing by inserting bearings. Therefore, selective fitting of the bearings
Crankshaft Main Bearing Remover/Installer Tool is not required when a crankshaft and bearings are
C-3059 Into the oil hole of crankshaft (Fig. 50). replaced.
(4) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell. REMOVAL
(2) Remove the oil pickup tube.
(8) Remove the timing chain cover and gasket.
Remove and discard the front crankshaft oil seal and
cover gasket.
(4) Remove Transmission (refer to Group 21,
Transmission).
(5) Remove the rear seal retainer. Remove and dis
card the crankshaft rear oil seal and retainer gasket.
(6) Identify main bearing caps before removal (Fig.
51). Remove bearing caps and bearings one at a time.
Fig. 50 Upper Main Bearing Removal and

INSTALLATION
procedures are to be cleaned and oiled before Instal
lation.
When installing a new upper bearing shell, slightly
chamfer the sharp edges from the plain side.
(1) Start bearing in place, and insert Crankshaft
Main Bearing Remover/Installer Tool C-3059 into oil
hole of crankshaft (Fig. 50).
(2) Slowly rotate crankshaft counterclockwise slid
(3) Lubricate the main journals with clean engine
oil. Install main bearing caps and bolts. Follow the 2 Fig. 51 Main Bearing Identification
step tightening sequence.
•• Step 1—Starting with bearing cap No.l, tighten (7) Remove the connecting rod bearing caps.
the bolts to 27 N-m (20 ft. lbs.) torque. (8) Lift the crankshaft straight out of the block.
• Step 2—Starting with bearing cap No.l, tighten
INSTALLATION PLUG TIMING
(1) Lubricate crankshaft main bearings with clean

engine oil.
(2) Install the crankshaft into the cylinder block.
(3) Lubricate the main journals with clean engine
oil. Install main bearing caps and bolts. Follow the 2
step tightening sequence.
• Step 1-—Starting with bearing cap No.l, tighten
• Step 2—Starting with bearing cap No.l, tighten
(4) Lubricate the connecting rod bearings and jour
nals with clean engine oil. Carefully install connect
ing rods to the crankshaft.
(5) Install the rear seal retainer with a new gasket
and oil seal. Use seal installer 6687 when installing
the oil seal. Fig. 52 Oil Pressure Relief Valve
(6) Install the timing chain cover with a new gas
ket and oil seal. OUTER INNER
(7) Prime oil pump by squirt oil in the oil filter ROTOR ROTOR
that has been filled with oil.
(8) Apply a rearward axial load of 667 N (150
Ibs-f) on crankshaft centerline, driving No.3 main cap
and thrust bearing against No.3 bulkhead. Repeat
procedure, driving crankshaft forward to align rear
flange of thrust bearings in a common plane. Front
face of No.l main cap must not extend forward in
front of face of No.l bulkhead.
(9) Install the oil pickup tube. Tighten the bolts to
16 N-m (144 in. lbs.) torque.
OIL PUMP
REMOVAL
(1) Remove the timing chain cover. TIMING CHAIN
COVER J9409-71
(2) Remove the relief valve plug, gasket, spring
and valve (Fig. 52). Discard the gasket.
(3) Remove oil pump cover (Fig. 53). Fig. 53 Oil Pump
(4) Remove pump rotors (Fig. 53). (7) Using a new pressure relief valve gasket,
install the relief valve plug. Tighten the plug to 20
INSTALLATION N-m (15 ft. lbs.) torque.
(1) Lubricate the pump rotors using petroleum (8) Install oil filter that has been filled with oil.
jelly or lubriplate and install in the timing chain
cover. Use new parts as required (Fig. 54). CRANKSHAFT REAR S E A L / RETAINER
(2) Position the oil pump cover onto the timing
chain cover. Tighten cover bolts to 14 N-m (125 in. REMOVAL
lbs.) torque. (1) Remove the transmission (refer to Group 21,
(3) Make sure that inner ring moves freely after Transmissions).
cover is installed. (2) Remove the oil pan.
(4) Install the timing chain cover. (3) Remove the rear seal retainer. Discard the oil
(5) Squirt oil into relief valve hole until oil runs seal and the gasket (Fig. 55).
out.
(6) Install the relief valve and spring.

(7) Install the transmission (refer to group 21,
Transmissions).
ENGINE CORE OIL—CAMSHAFT PLUGS

Engine core plugs have been pressed into the oil
galleries behind the camshaft thrust plate. This will
reduce internal leakage and help maintain higher oil
pressure at idle.
REMOVAL
(1) Using a blunt tool such as a drift or a screw
driver and a hammer, strike the bottom edge of the
cup plug (Fig. 56).
(2) With the cup plug rotated, grasp firmly with
pliers or other suitable tool and remove plug (Fig.
56).
CYLINDER
Fig. 54 Priming Oii Pump.

INSTALLATION
(1) Thoroughly clean inside of cup plug hole i n cyl
inder block or head. Be sure to remove old sealer.
(2) Make certain the new plug is cleaned of all oil
or grease.
(3) Coat edges of plug and core hole with Mopar®
Fig. 55 Crankshaft Rear Seal Retainer Gasket Maker, or equivalent.
INSTALLATION
(1) Wash all parts i n a suitable solvent and inspect CAUTION: DO NOT drive cup plug into the casting
carefully for damage or wear. as restricted coolant flow can result and cause seri
(2) Position the rear seal i n the retainer. ous engine problems.
(3) Using Special Tool 6687, position the retainer
and oil seal over the crankshaft. Install the bolts and (4) Using proper drive plug, drive plug into hole.
tighten to 22 N-m (16 ft. lbs.) torque. The sharp edge of the plug should be at least 0.50
(4) The seal face surface must be within 0.508 mm mm (0.020 inch) inside the lead-in chamfer.
(0.020 in) full Indicator movement relative to rear It is not necessary to wait for curing of the sealant.
face of crankshaft. I f out of limits, gently tap the The cooling system can be filled and the vehicle
high side into the retainer. placed in service immediately.
(5) Add a small amount of Mopar® Silicone Rubber
Adhesive Sealant at split-line.

Reamer O / S Valve Guide Size
VALVE SERVICE
0.076 mm 8.026 - 8.052 mm
(0.003 in.) (0.316-0.317 in.)
VALVE GUIDES
Measure valve stem guide clearance as follows: 0.381 mm 8.331 -8.357 mm
(1) Install Black Valve Guide Sleeve Tool C-6819 (0.015 in.) (0.328-0.329 in.)
over valve stem for the INTAKE valve and install
valve (Fig. 57). The special sleeve places the valve at
the correct height for checking with a dial indicator.
(2) Install Silver Valve Guide Sleeve Tool C-6818 J9309-30
over valve stem for the EXHAUST valve and install
valve. The special sleeve places the valve at the cor Fig. 59 Reamer Sizes
rect height for checking with a dial indicator. (5) Slowly turn reamer by hand and clean guide
thoroughly before installing new valve. Ream the
valve guides from standard to 0.381 mm (0.015
inch). Use a 2 step procedure so the valve
guides are reamed true in relation to the valve
seat:
REFACING VALVES AMD VALVE SEATS

The intake and exhaust valves have a 45° face
angle and a 45° to 44 1/2° seat angle (Fig. 60).
CONTACT
Fig. 57 Positioning Vaive Spacer Tool (Typical) POINT
(3) Attach Dial Indicator Tool C-3339 to cylinder

head and set i t at right angle of valve stem being
measured (Fig. 58).
A - SEAT WIDTH - INTAKE 1.016-1.524 mm (0.040-0.060 in.)

EXHAUST 1.016-1.524 mm (0.040-0.060 in.)
B - FACE A N G L E (INTAKE & EXHAUST)
C - SEAT ANGLE (INTAKE & EXHAUST)
D - CONTACT SURFACE
J9409-133
Fig. 58 Measuring Valve Guide Wear Fig. 60 Valve Face and Seat Angles
(4) Move valve to and from the indicator. The total WALWES
dial indicator reading should not exceed 0.432 mm
(0.017 inch). Ream the guides for valves with over
size stems i f dial indicator reading is excessive or i f
the stems are scuffed or scored.
Service valves with oversize stems are available WALWE SEATS
(Fig. 59).
(1) When refacing valve seats, i t is important that
the correct size valve guide pilot be used for reseat-
BR — — — _ _ 8.0L ENGINE 9 - 153

TORQUE
WRENCH
INTAKE EXHAUST
VALVE VALVE
FACE
* STEM-
VALVE SPRING
TESTER
VALVE SPRING
RETAINER LOCK
GROOVE
9509-79
J9209-127
Fig. 62 Testing Valve Spring for Compressed
Length
Fig. 61 intake and Exhaust Valves
CYLINDEi BLOCK
ing stones. A true and complete surface must be
Remove the engine assembly from the vehicle.
obtained.
(2) Measure the concentricity of valve seat using a DISASSEMBLE
dial indicator. Total runout should not exceed 0.038 ( 1 ) Remove the cylinder head and valve train.
mm (0.0015 inch) total indicator reading. ( 2 ) Remove the intake system.
(3) Inspect the valve seat with Prussian blue to (3) Remove the timing cover and timing chain with
determine where the valve contacts the seat. To do sprockets.
this, coat valve seat LIGHTLY with Prussian blue (4) Remove the oil pan.
then set valve in place. Rotate the valve with light ( 5 ) Remove the piston-connecting rod assemblies.
pressure. I f the blue Is transferred to the center of ( 6 ) Remove the crankshaft and bearings.
valve face, contact is satisfactory, i f the blue is trans
ferred to the top edge of Valve face, lower valve seat ASSEMBLE
with a 15° stone. I f the blue is transferred to bottom ( 1 ) Install crankshaft and bearings.
edge of valve face raise valve seat with a 60° stone. (2) Install the piston/connecting rod assembly
(4) When seat Is properly positioned the width of (3) Install the oil pan.
valve seats should be 1.016-1.524 mm (0.040-0.060 ^ (4) Install timing cover, timing chain and sprock
Inch). ets.
• ( 5 ) Install the cylinder head and valve train.
VALVE SPRING INSPECTION (6) Install the engine into the vehicle.
Whenever valves have been removed for inspection, (7) Install intake system.
the spring to be tested is 1 - 5 / 1 6 inch. Turn table of CLEANING AND INSPECTION
Universal Valve Spring Tester Tool until surface is in
line with the 1 - 5 / 1 6 inch mark on the threaded stud. CYLINDEi HEAPS
Be sure the zero mark is to the front (Fig. 6 2 ) . Place
spring over stud on the table and lift compressing CLEANING
lever to set tone device. Pull on torque wrench until Clean all surfaces of cylinder block and cylinder
ping is heard. Take reading on torque wrench at this heads. Be sure material does not fall into the lifters
instant. Multiply this reading by 2 . This will give the and surrounding valley.
spring load at test length. Fractional measurements Clean cylinder block front and rear gasket surfaces
are indicated on the table for finer adjustments. using a suitable solvent.
Refer to specifications to obtain specified height and Clean the exhaust manifold to cylinder head mat
allowable tensions. Discard the springs that do not ing areas.
INSPECTION
Imped all surfaces with a straightedge i f there is
any reason to suspect leakage. The out-of-flatness
I - 154 8.DL ENGINE

specifications are 0.0007 mm/mm (0.0004 inch/inch), Measure thickness (Fig. 64) (Fig. 65)and diameter
0.127 mm/152 mm (0.005 inch/6 inches) any direction of rotors. I f either rotor thickness measures 14.956
or 0.254 mm (0.010 inch) overall across head. I f mm (0.5876 Inch) or less, or i f the diameter is 82.45
exceeded, either replace head or lightly machine the mm (3.246 inches) or less, replace rotor set.
head surface.
The cylinder head surface finish should be
1.78-4.57 microns (15-80 mlcroinches).
inspect push rods. Replace worn or bent rods. >
Inspect rocker arms. Replace i f worn or scored.
OIL PAN
CLEANING
engine.
Clean oil pan In solvent and wipe dry with a clean
cloth.
Clean oil screen and pipe thoroughly In clean sol
vent. Inspect condition of screen.
INSPECTION Fig. 64 Measuring Outer Rotor Thickness

OIL P U i P
CLEANING
Wash all parts In a suitable solvent and inspect
carefully for damage or wear.
INSPECTION
smooth. Replace pump cover i f scratched or grooved.
9309-70
(Fig. 63). I f a 0.076 mm (0.003 inch) feeler gauge can
be inserted between cover and straightedge, cover
should be replaced. Fig. 65 Measuring Inner Rotor Thickness
Slide outer rotor into timing chain cover pump
body. Press rotor to the side with your fingers and
measure clearance between rotor and pump body
(Fig. 66). I f clearance is 0.19 mm (0.007 inch) or
more, and outer rotor is within specifications, replace
timing chain cover.
Install inner rotor into timing chain cover pump
body (Fig. 67). Inner rotor should be positioned with
chamfer up or toward engine when cover is installed.
This allows easy installation over crankshaft. I f
mm (0.006 inch) or more, replace both rotors.
Place a straightedge across the face of the timing
chain cover pump body, between bolt holes (Fig. 68).
I f a feeler gauge of 0.077 mm (0.003 inch) or more
>-68
can be inserted between rotors and the straightedge,
Fig. 68 Checking Oii Pump Cower Flatness
BR — • • — • — • • — 8.0L E i i i i E 9 - 155
Fig. 66 Measuring Outer Rotor Clearance in Cower Fig. 68 Measuring Clearance Ower Rotors
If oil pressure was low and pump is within specifi
CYLINDER BLOCK
GLEAMING
INSPECTION
round and taper with Cylinder Bore Indicator Tool,
Special tool 6879 or equivalent. The cylinder block
should be bored and honed with new pistons and
Fig. 67 Measuring Inner Rotor Clearance in Cower rings fitted if:
and the rotors are within specifications, replace tim (0.005 inch) out-of-round.
ing chain cover. • The cylinder bores show a taper of more than
Inspect oil pressure relief valve plunger for scoring 0.254 mm (0.010 inch).
and free operation in its bore. Small marks may be • The cylinder walls are badly scuffed or scored.
removed with 400-grit wet or dry sandpaper. Boring and honing operation should be closely coor
The relief valve spring has a free length of approx dinated with the fitting of pistons and rings so spec
imately 49.5 mm (1.95 inches). The spring should ified clearances may be maintained.
test between 100 and 109 N (22.5 and 24.5 pounds)
when compressed to 34 mm (1-11/32 inches). Replace
spring that fails to meet these specifications.
8.0L ENGINE
SPECIFICATIONS—8.0L ENGINE
Camshaft Crankshaft (Cont.)
Bore Diameter Main Bearing Diametrical Clearance

No 1 5 3 . 1 6 - 5 3 . 1 9 mm No.l - No.6 0.0051 - 0.058 mm
(2.093 - 2.094 in) (0.0002 - 0.0023 in)
No 2 .......52.76 - 52.78 mm Max. Allowable ....0.071 mm
(2.077 - 2.078 in) (0.0028 in)
No 3 ..52.35 - 52.37 mm End Play ...0.076 - 0.305 mm
(2.061 - 2.062 in) ( 0 . 0 0 3 - 0 . 0 1 2 in)
No 4 5 1 . 9 4 - 5 1 . 9 7 mm Max. Allowable .0.381 mm
(2.045 - 2.046 in) (0.015 in)
No 5 . .51.54 - 51.56 mm Main Bearing Journals
(2.029 - 2.030 in) Diameter 76.187 - 76.213 mm
No 6 48.74 - 48.77 mm (2.9995 - 3.0005 in)
(1.919- 1.920 in) Out-of-Round (Max.) 0.0254 mm
Diametrical Clearance (0.001 in)
N o . l & No.3 - No.6 .0.0254 - 0.0762 mm (0.001 in)
(0.001 - 0.003 in)
No 2 0.0381 - 0.0889 mm Cylinder Block
(0.0015-0.0035 in)
End Play . 0 . 1 2 7 - 0 . 3 8 1 mm Cylinder Bore
( 0 . 0 0 5 - 0 . 0 1 5 in) Diameter 101.60- 101.61 mm
Bearing Journal Diameter (4.0000 - 4.0005 in)
No 1 . . ..53.11 - 53.14 mm (0.005 in)
(2.091 - 2.092 in) Taper (Max.) 0.254 mm
No 2 . ..52.69-52.72 mm (0.010 in)
(2.0745 - 2.0755 in) Tappet Bore Diameter 22.982 - 23.010 mm
No 3 ....52.30 - 52.32 mm (0.9048 - 0.9059 in)
(2.059 - 2.060 in)
No 4 5 1 . 8 9 - 5 1 . 9 2 mm Cylinder Head
(2.043 - 2.044 in)
No 5 51.49 - 51.51 mm Compression Pressure 1172 - 1310 kPa
(2.027 - 2.028 in) ( 1 7 0 - 190 psi)
No 6 48.69 - 48.72 mm Gasket Thickness (Compressed) 0.991 - 1.118 mm
(1.917- 1.918 in) (0.039 - 0.044 in)
Valve Seat
Connecting Rods Angle 44.5°
Runout (Max.) 0.076 mm
Bearinq Clearance 0.005 - 0.074 mm (0.003 in)
(0.0002 - 0.0029 in) Width (Finish)
Piston Pin Bore Diameter ...24.940 - 24.978 mm Intake & Exhaust 1.02 - 1.52 mm
(0.9819-0.9834 in) (0.040 - 0.060 in)
Side Clearance (Two Rods) 0.25 - 0.46 mm Guide Bore Diameter (Std.) 7.95 - 7.98 mm
(0.010-0.018 in) ( 0 . 3 1 3 - 0 . 3 1 4 in)
Total Weight (Less Bearing) • 744 grams
(26.24 oz) Hydraulic Tappets
Crankshaft Body Diameter 22.949 - 22.962 mm

(0.9035 - 0.9040 in)
Connecting Rod Journal Clearance in Block (Diametrial) 0.2030 - 0.0610 mm
Diameter 53.950 - 53.975 mm (0.0008 - 0.0024 in)
( 2 . 1 2 4 - 2 . 1 2 5 in) Plunger Travel Minimum (Dry) 4.24 mm
Out-of-Round (Max.) 0.0254 mm (0.167 in)
(0.001 in) Push Rod Length 195.52- 196.02 mm
Taper (Max.) 0.0254 mm (7.698 - 7 . 7 1 7 in)
V
(0.001 in)
J9509-141
SPECIFICATIONS {Continued)
Oil Pump Piston Rings
Clearance over Rotors (Max.) 0.1906 mm Ring Gap

(0.0075 in) Compression Rings 0.254 - 0.508 mm
Cover Out-of-Flat (Max.) ....0.051 mm (0.010-0.020 in)
(0.002 in) Oil Control (Steel Rails) 0.381 - 1.397 mm
Inner Rotor Thickness (Min.) ..............14.925 - 14.950 mm ( 0 . 0 1 5 - 0 . 0 5 5 in)
(0.5876 - 0.5886 in) Ring Side Clearance
Outer Rotor Compression Rings 0.074 - 0.097 mm
Clearance (Max.) 0.1626 mm (0.0029 - 0.0038 in)
(0.006 in) Oil Ring (Steel Rails) 0.185 - 0.246 mm
Diameter (Min.) .....82.461 mm (0.0073 - 0.0097 in)
(3.246 in) Ring Width
Thickness (Min.) 14.925 mm Compression Rings 4.115 - 4.369 mm
(0.5876 in) ( 0 . 1 6 2 - 0 . 1 7 2 in)
Tip Clearance between Rotors (Max.) ....0.584 mm Oil Ring (Steel Rails) 2.591 - 2.743 mm
(0.0230 in) ( 0 . 1 0 2 - 0 . 1 0 8 in)
Oil Pressure (Engine Hot) Valves
At Curb Idle Speed * 83 - 172 kPa Face Angle 45°

( 1 2 - 2 5 psi) Head Diameter
At 3000 rpm 345-414kPa Intake 48.640 - 48.900 mm
(50 - 60 psi) ( 1 . 9 1 5 - 1 . 9 2 5 in)
Exhaust 41.123 - 41.377 mm
•CAUTION: If pressure is ZERO at curb idle, DO NOT ( 1 . 6 1 9 - 1 . 6 2 9 in)
run engine at 3,000 rpm. Length (Overall)
Intake 145.19- 145.82 mm
Pistons (5.716-5.741 in)
Exhaust .145.54- 146.18 mm
Land Clearance (Diametrical) 0.013 - 0.038 mm (5.730 - 5.755 in)
(0.0005 - 0.0015 in) Lift (Zero Lash)
Piston Length 82.5 mm Intake 9.91 mm
(3.25 in) (0.390 in)
Piston Ring Groove Diameter Exhaust 10.34 mm
No.l & N o . 2 9 1 . 3 0 - 9 1 . 5 5 mm (0.407 in)
(3.594 - 3.604 in) Valve Stem Tip Height 47.50 -48.13 mm
No.3 9 2 . 9 0 - 9 3 . 1 5 mm (1.870- 1.895 in)
(3.657 - 3.667 in) Stem Diameter 7.900 - 7.920 mm
Weight 463 - 473 grams (0.311 -0.312 in)
( 1 6 . 3 3 - 1 6 . 6 8 oz) Stem-to-Guide Clearance
Intake & Exhaust 0.025 - 0.076 mm
Piston Pins (0.001 - 0.003 in)
Max. Allowable (Rocking Method) 0.4318 mm
Clearance (0.017 in)
In Piston 0.2489 - 0.5537 mm
(0.0098-0.0218 in) J9409-83
In Rod (Interference) 0 . 0 1 8 - 0.061 mm
(0.0007 - 0.0024 in)
Diameter ....24.996 - 25.001 mm
(0.9841 - 0.9843 in)
End Play ...............NONE
Length 6 7 . 8 1 8 - 6 8 . 3 2 6 mm
(2.670 - 2.690 in)
9 - 158 8.0L ENGINE — BR

(1.967 in) Closes (ATC) ...25°
Spring Tension Opens (BBC) ...60°
Valve Closed .369 - 405 N ©41.66 mm Duration ...265°
(81 - 8 9 lbs @1.640 in) Intake Valve
Valve Open .865 - 956 N @30.89 mm Closes (ABC) .61°
(190 - 210 lbs ®1.216 in) Opens (BTC) ....6°
Number of Coils 6.79 Duration 246°
Wire Diameter 4.496 mm Valve Overlap .....31 °
(0.177 in)
J9509-142
CONDITION IDENTIFICATION LOCATION OF IDENTIFICATION
CRANKSHAFT JOURNALS RorM Milled flat on no. 8 crankshaft counterweight

(UNDERSIZE) M-2-3 etc. (indicating no. 2 and 3 main bearing
0.0254 mm (0.001 in.) journal)
and/or
R-1 -4 etc. (indicating no. 1 and 4 connecting rod
journal)
CYLINDER BORES A Following engine serial number.

(OVERSIZE)
0.508 mm (0.020 in.)
HYDRAULIC TAPPETS Diamond-shaped stamp top pad - front of

(OVERSIZE) engine and flat ground on outside surface of
0.2032 mm (0.008 in.) each O/S tappet bore.

J9209-142
BR •—• • • 8.0L ENGINE I - 159
mmm
DESCRIPTION TORQUfc DESCRIPTION TORQUE
Camshaft Bolt 75 N » m (55 ft. lbs.) Intake Manifold Bolts (Upper) 22 N«^m (16ft. lbs.)
Camshaft Thrust Plate Torx Bolts.............. 2 2 N * m (16 ft. lbs.) Oil Filter 9 N«*m (80 in. lbs.)
Coil Pack Bracket Bolts........ 21 N * m (190 in. lbs.) +45°
Connecting Rod Cap Bolts 61 N»m (45 ft. lbs.) Oil Filter Connector 46 N«•m (34 ft. lbs.)
Crankshaft Main Bearing Cap Bolts Oil Pan Bolts (1/4-20) 11 N«*m (96 in. lbs.)
1 st Step 2 7 N * m (20 ft. lbs.) Oil Pan Stud Bolts 16 N«*m (144 in. lbs.)
2nd Step 1 1 5 N * m (85 ft. lbs.) Oil Pan Bolts (5/16-18) 16 N«»m (144 in. lbs.)
Crankshaft Pulley/Damper Bolt 1 8 3 N T n (135 ft. lbs.) Oil Pan Drain Plug 34 N«*m (25 ft. lbs.)
Crankshaft Rear Seal Retainer Bolts 2 2 N » m (16 ft. lbs.) Oil Pan Pick-Up Tube Bolts 16 N«*m (144 in. lbs.)
Cylinder Head Bolts Oil Pump Attaching Bolts 41 N«i (30 ft. lbs.)
m
1st Step 58 N«m (43 ft. lbs.)

Oil Pump Cover Bolts 14 N«*m (125 in. lbs.)
(105 ft. lbs.)
2nd Step 14 3 N * m
(144 in. lbs.) Oil Pump Pressure Relief Plug 20 N«»m (15 ft. lbs.)
Cylinder Head Cover Bolts/Studs 16N»m
Rear Oil Seal Retainer Bolts 22 N«»m (16ft. lbs.)
Drive Plate-to-Crankshaft Bolts 75 N»m (55 ft. lbs.)
Rocker Arm Bolts 28 N«i m
(21 ft. lbs.)
Drive Plate-to-Torque Converter Bolts 7 5 N » m (55 ft. lbs.)
Spark Plugs 41 N«» m
(30 ft. lbs.)
EGR Tube Nut 3 4 N » m (25 ft. lbs.)
(174 in. lbs.) Starter Mounting Bolts 68 N«»m (50 ft. lbs.)
EGR Bolts 20NTTI
Timing Chain Cover Bolts 47 N«»m (35 ft. lbs.)
Engine Support Bracket/Cushion
Thru-Bolt 68 N»m (50 ft. lbs.) Thermostat Housing Bolts 25 N«»m (220 in. lbs.)
Engine Support Bracket/Cushion Throttle Body Nuts 11 N«•m (96 in. lbs.)
Mounting Bolts 47N*m (35 ft. lbs.) Torque Converter Drive Plate Bolts 31 N«i m
(270 in. lbs.)
Exhaust Manifold-to-Cylinder Transfer Case-to-lnsulator Mounting
Head Bolts.. 22N*m (16 ft. lbs.) Plate Nuts. 204 N«i m (150 ft. lbs.)
Flywheel-to-Crankshaft Bolts 75 N * m (55 ft. lbs.) Transmission Support Bracket Bolts 102 N<i (75 ft. lbs.)
m
Generator Mounting Bolt 41 N * m (30 ft. lbs.) Transmission Support Cushion Bolts 47 N<i m (35 ft. lbs.)
Generator-to-Intake Manifold Transmission Support Cushion
Bracket Bolts 41 N«m (30 ft. lbs.) Stud Nuts 47 N<•m (35 ft. lbs.)
Heat Shield Nuts 2 0 N » m (175 in. lbs.] Water Pump-to-Chain Case Cover Bolt... . 41 N«»m (30ft.lbs.)
Hydraulic Tappet Yoke Retaining Water Pump Pulley Bolts 22 N<i m (16ft. lbs.)
Spider Bolts 22 N*m (16ft. lbs.)
Intake Manifold Bolts (Lower) 5 4 N * m (40 ft. lbs.)
J9509-143
SPECIAL TOOLS
8.0L ENGINE
Black Valve Guide Sleeve Tool C6819

Valve Compressor Adapting Stud Tool 6715
Silver Vaive Guide Sleeve Tool C6818

Valve Spring Compressor Adapter Tool 6716A
Valve Spring Compressor Tool MD-998772A Dial Indicator

80Tool
11d42b C3389
Valve Spring Compressor Screw Tool 6756 Crankshaft Pulley/Damper Installer Tool C8688
BR — _ _ — . 8.0L ENGINE 9
Crankshaft Sprocket Puller Tool 6444 Front Oil Seal Installer Tool 6806
Crankshaft Sprocket Puller Jaws Tool 6820 Front Oil Seal Installer Toot 6761
8011d423
Crankshaft Sprocket Installer Tool 3718 Camshaft Bearing Installer Tool C3132A
Crankshaft Sprocket Installer Tool MD990799

Compression Ring Installer Tool C4184
Seal Installer Tool 6687 Seal Installer Tool 6687

BR 5.9L (DIESEL) ENGINE 9 -163
5.9L (DIESEL) ENGINE
INDEX
page page
GENERAL INFORMATION ENGINE REAR MOUNT 179

OIL FILTER 163 FLYWHEEL RING GEAR 197
PISTON GRADING 163 GEAR HOUSING COVER 184
DESCRIPTION AND OPERATION GEAR HOUSING 185
ENGINE DESCRIPTION 164 OIL FILTER BYPASS VALVE 198
LUBRICATION SYSTEM 164 OIL PAN AND SUCTION TUBE 191
OIL P R E S S U R E REGULATOR VALVE 166 OIL P R E S S U R E REGULATOR VALVE AND
TIMING PIN 166 SPRING 199
SERVICE PROCEDURES OIL PUMP 198
CAM BORE REPAIR 173 PISTON AND CONNECTING ROD ASSEMBLY . 192
CONNECTING ROD BEARING AND ROCKER L E V E R S AND PUSH RODS 182
CRANKSHAFT JOURNAL CLEARANCE 174 TAPPET 190
CRANKSHAFT REWORK 175 TIMING PIN HOUSING ASSEMBLY 186
CYLINDER BLOCK CUP PLUG TIMING PIN 186
REPLACEMENT 174 VALVES AND VALVE SPRINGS 184
CYLINDER BLOCK REFACING . 170 DISASSEMBLY AND ASSEMBLY
CYLINDER BORE REPAIR 171 PISTON AND CONNECTING ROD ASSEMBLY . 200
CYLINDER B O R E S — D E - G L A Z E 170 ROCKER L E V E R S . 199
MAIN BEARING CLEARANCE 178 CLEANING AND INSPECTION
OIL FILTER 166 CAMSHAFT 205
PISTON GRADING P R O C E D U R E 174 CRANKSHAFT 208
VALVE S E R V I C E 167 CYLINDER BLOCK 206
REMOVAL AND INSTALLATION CYLINDER HEAD 202
CAMSHAFT 189 OIL C O O L E R ELEMENT AND GASKET 202
CRANKSHAFT FRONT S E A L 195 OIL PUMP 205
CRANKSHAFT GEAR 197 PISTON AND CONNECTING ROD ASSEMBLY . 207
CRANKSHAFT REAR S E A L HOUSING 196 TAPPET 204
CRANKSHAFT REAR S E A L 195 VALVES AND VALVE SPRINGS 203
CRANKSHAFT 193 ADJUSTMENTS
CYLINDER HEAD 182 VALVE CLEARANCE ADJUSTMENT 209
ENGINE ASSEMBLY 180 SPECIFICATIONS
ENGINE FRONT MOUNTS 178 5.9L (DIESEL) ENGINE 210
G E N E R A L INFORMATION OIL FILTER

When replacing the oil filter, use replacement filter
PISTON GRADING specified in your Operator's Manual.
When rebuilding an engine with the original cylin
der block, crankshaft and pistons, make sure the pis CAUTION: The internal filtering medium of some
tons are installed in the original cylinder. filters has been known to disintegrate. Debris from
If replacing the piston(s), make sure the replace failed filters may plug the piston oil cooling noz
ment piston(s) are the same grade as the original pis zles, resulting in scuffed pistons and eventual
ton. engine failure.
If a new cylinder block or crankshaft is used, the
piston grading procedure MUST be performed to
determine the proper piston grade for each cylinder.
9 - 164 5.9L (DIESEL) ENGINE
DESCRIPTION AND O P E R A T I O N LUBRICATION SYSTEM

The engine uses a gerotor type lubricating pump.
ENGINE DESCRIPTION The machined cavity in the block is the same for all
The 5.9 Liter (359 CID) six-cylinder diesel engine engines. The pressure regulating valve is designed to
is an In-line valve in head type (Fig. 1). keep the lubricating oil pressure from exceeding
4 4 9 k P a (65 PSI). When the lubricating oil pressure
Engine Type. In-line 6 (Diesel-Turbo) from the pump is greater the 4 9 9 k P a (65 PSI), The
Bore and Stroke 102.0 x 120.0 mm (4.02 x 4.72 in.) valve opens uncovering the dump port so part of the
Displacement 5.9L (359 cu. in.) lubricating oil is routed to the oil pan. Because of
Compression Ratio 17.5:1 manufacturing tolerances of the components and the
Torque (Automatic) ..542 N«m (400 ft. lbs.) @ 1600 rpm oil passages, the lubricating oil pressure can differ as
(Manual) 569 N®m (420 ft. lbs.) @ 1600 rpm much as 69 kPa (10 PSI) between engines.
Firing Order 1 -5-3-6-2-4 The engines use full flow, plate type oil coolers. The
Lubrication Pressure Feed - Full Flow oil flows through a cast passage in the cooler cover and
Filtration w/Bypass Valve through the element where it is cooled by the engine
Engine Oil Capacity 9.5L (10.0 Qts) w/Filter coolant flowing past the plates of the elements. After
Cooling System Liquid Cooled - Forced Circulation the oil is cooled, it flows through the full flow oil filter.
Cooling Capacity 23L (24 Qts) The lubricating oil cooler cover contains a bypass
Cylinder Block Cast Iron valve the will let the lubricating oil flow bypass a
Crankshaft Induction Hardened Forged Steel plugged filter. The valve is designed to open when
Cylinder Head Cast Iron the pressure drop across the filter is more than 138
Combustion Chambers High Swirl Bowl kPa (20 PSI), as with a plugged filter and lets the
Camshaft Chilled Ductile Iron lubricating oil continue on through the engine. When
Pistons ..Cast Aluminum a filter becomes plugged, an oil pressure decrease of
Connecting Rods. Forged Steel 60 kPa (10 PSI) or less from normal operating pres
sure can be observed on the vehicle lubricating oil
J9409-12 pressure gauge. This allows unfiltered oil into the
engine. This condition should be avoided by changing
Fig. 1 Diesei Engine Description the filter at each oil change.
This engine is designed for No.2 Diesel Fuel. Only The turbocharger receives filtered, cooled and pressur
use No.l Diesel Fuel where extended arctic condi ized lubricating oil through a supply line from the filter
tions exist (below -23°C or -10°F). head. A drain line connected to the bottom of the turbo
Engine lubrication system consists of a gerotor charger housing returns the lubricating oil to the lubri
type oil pump and a full flow oil filter with a bypass cating oil pan through a fitting in the cylinder block.
valve. The main bearings and the valve train are lubri
The cylinders are numbered from front to rear; 1 to cated by pressurized oil directly from the main oil
6. The firing order is 1-5-3-6-2-4 (Fig. 2). gallery, the other power components, connecting rods,
pistons, and camshaft receive pressurized oil directly
from the main oil gallery. Passages in the crankshaft
supply oil to the connecting rods bearings. The oil is
supplied to the camshaft journals through passages
in the main bearings saddles. Smaller passages in
the main bearings saddles supply oil to the pistons
cooling nozzles. The spray from the nozzles also pro
vides lubrication for the piston pins.
Lubrication for the valve train is supplied through
0 0 0 © 00: separate passages in the cylinder block. Oil flows

through the passages and across the oil transfer slot
in the cylinder head gasket. From the transfer slot,
the oil flows around the outside diameter at the cyl
.1....: , J
inder capscrew, across a slot in the bottom of the
rocker lever support, and up the vertical passage in
J9409-107
the support. From these passages, oil flows through
Fig. 2 Firing Order
passages in the rocker lever shaft to lubricate the
rocker levers. The oil from the channel lubricates the
The engine data plate is located on the driver side valves stems, push rods, and tappets.
of the engine forward of the fuel injection pump.
9 - 166 5.9L (DIESEL) ENGINE BR
DESCRIPTION A U D OPERATION {Continued)
LUBRICATING
OIL COOLER
FULL FLOW
FILTER
FILTER
BYPASS
VALVE
dm
TURBOCHARGER
LUBRICATION
TO FILTER
TO OIL
PAN
'CLOSED OPEN
FROM MAIN OIL

PUMP RIFLE
i
^ TO COOLER
GEROTOR
PRESSURE LUBRICATING FILTER BYPASS
REGULATING OIL PUMP VALVE
VALVE J9509-76
Fig. 4 Lubricating System Passages
OIL PRESSURE REGULATOR-VALVE . SERVICE PROCEDURES

When oil pressure from the oil pump exceeds 448
kPa (65 psi), the regulator valve opens to allow oil to OIL FILTER
drain back into the pan. When replacing the oil filter, use replacement filter
specified in your Operator's Manual.
TIMING PIN
The timing pin is used for three different proce CAUTION: The internal filtering medium of some
dures: filters has been known to disintegrate. Debris from
• Valve adjustment failed filters may plug the piston oil cooling noz
• Top Dead Center (TDC) location zles, resulting in scuffed pistons and eventual
• Fuel injector pump timing procedure engine failure.
BR 5 JL (DIESEL) ENGINE 9 - 167
S E R V I C E P R O C E D U R E S {Continued)
REMOVAL ¥AL¥E SEiflCE
WARNING: HOT OIL CAN CAUSE PERSONAL INJURY. VALVE GUIDE INSTALLATION
(1) Operate the engine until the water tempera THIN WALL—SEftWiCE GUIDES
ture reaches 60°C (140°F). Shut the engine off. Machine the cylinder head valve guide bores to
(2) Use a container that can hold at least 14 liters 11.125 ±0.013 mm (0.4380 ±0.0005 inch) in diameter
(15 quarts) to hold the used oil. Remove the oil drain (Fig. 5).
plug and drain the used engine oil into the container. Service valve guides must be centered with valve
(3) Always check the condition of the used oil. This seats within 0.35 mm (0.01378 inch) diameter. They
can give you an indication of some engine problems must also be square with the combustion face within
that might exist. 0.10 mm (0.004 inch) at 50.0 mm (1.9685 inch)
• Thin, black oil indicates fuel dilution. radius.
• Milky discoloration indicates coolant dilution. Lubricate the valve guides with oil and press the
(4) Clean the area around the lubricating oil filter guides flush to the bottom of the bosses.
head. Remove the filter using a 90-95 mm filter Trim off the top of the valve guides flush to top of
wrench. guide bosses, i f necessary.
(5) Clean the gasket surface of the filter head. The Machine the valve guide bores to 8.029 ±0.010 mm
filter canister O- Ring seal can stick on the filter (0.3161 ±0.0004 inch) - (Fig. 5).
head. Make sure it is removed. The valve guide bore - must be centered with the
valve seat within 0.35 mm (0.0138 inch) diameter. I t
INSTALLATION
also must be square with the combustion face within
(1) Fill the oil filter element with clean oil before
0.010 mm (0.0004 inch) at 50.0 mm (2.0 inch) radius.
installation. Use the same type oil that will be used
in the engine. VALVE GUIDE BORES CYLINDER
(2) Apply a light film of lubricating oil to the seal HEAD
ing surface before installing the filter.
CAUTION: Mechanical over-tightening may distort

the threads or damage the filter element seal.
(3) Install the filter as specified by the filter man

ufacturer. EXHAUST
(4) Clean the drain plug and the sealing surface of
the pan. Check the condition of the threads and seal
ing surface on the oil pan and drain plug. INTAKE
(5) Install the drain plug using a new sealing
washer. Tighten the plug to 80 N-m (60 ft. lbs.)
CYLINDER HEAD VALVE GUIDE BORES
torque.
(6) Use only High-Quality Multi-Viscosity lubricat CYLINDER HEAD VALVE GUIDE BORES
ing oil in the Cummins Turbo Diesel engine. Choose 11.125 ±0.013 mm (0.438 ± 0.0005 in)
the correct oil for the operating conditions outlined in VALVE GUIDE BORES
Group 0, Lubrication and Maintenance. 8.029 ± 0 . 0 1 0 mm (0.3161 ±0.0004 in)
(7) Fill the engine with the correct grade of new
oil. The engine capacity is 9.46 liters (10 quarts) in
J9109-136
the crankcase and 0.95 liters (1 quart) in the lubri
cating oil filter. F/g. 5 Service Vaive Guides—Thin Wall
(8) Start the engine and operate it at idle for sev
THICK WALL—SERVICE GUIDES
eral minutes. Check for leaks at the filter and drain
plug. Machine the cylinder head valve guide bores to
(9) Stop the engine. Wait approximately 15 min 14.000 ±0.013 mm (0.5512 ±0.0005 inch) diameter
utes to let the oil i n the upper parts of the engine to (Fig. 6).
drain back to the oil pan. Check the oil level again. Valve guides must be centered with valve seats
Add oil as necessary to bring the level to the H within 0.35 mm (0.01378 inch) diameter. Valve
(High) mark on the dipstick. guides must also be square with the combustion face
within 0.10 mm (0.004 inch) at 50.0 mm (2.0 inch)
radius.
i - 168 5 J L (DIESEL) ENGINE BR

Lubricate the valve guides with oil and press in Install the valves in their respective bores and
the guides to 12.25 ±0.50 mm (0.4823 ±0.020 inch) measure the depth again (Fig. 7). Record the depth of
protrusion above the cylinder head. each valve.
Ream the bores to 8.029 ±0.010 mm (0.3161 The grinding depth is the difference between the
±0.0004 inch) - (Fig. 6). measurement before grinding and the measurement
after grinding. The grinding depth maximum limit
VALVE GUIDE BORES
(integral seats only) is 0.254 mm (0.010 inch). Service
CYLINDER
HEAD
valve seats are available for over limit integral valve
seats.
Identify ground valve seats by stamping the cylin
der head.
Install the valves in their designated locations and
measure the depth of each. The valve depth limit
(Integral and Inserted Seats) is 0.99 mm to 1.52 mm
(0.039 inch to 0.060 inch). Replace the valve i f the
EXHAUST depth is over this limit.
INTAKE
Apply a light coat of valve lapping compound to
each valve and lap each valve to its mating seat.
Remove the valves and clean lapping compound
CYLINDER HEAD VALVE GUIDE BORES from the valves and seats.
Measure the valve seat width indicated by the lap
CYLINDER HEAD VALVE GUIDE BORES ping surface. The valve seat width limit is 1.50-2.00
14.0O) ±0.013 mm (0.5512 ± 0.0005 in) mm (0.060-0.080 inch).
VALVE GUIDE BORES I f required, grind the areas with a 60° stone and a
8.029 ±0.010 mm (0.3161 ±0.0004 in) 15° stone to center the seat on the valve face. Main
J9109-137
tain the valve seat width limits (Fig. 8).
GRIND TO 15°
VALVE
Fig. 6 Service Waive Guides—Thick Wail
XfAiJSfE SEATS
INTEGRAL VALVE SEAT GRINDING

After resurfacing the valves and determining that
all valves meet specifications, install the valves i n
their designated locations and measure valve depth
(Fig. 7). The valve depth is the distance from the
valve face to the head deck. Record the depth of each
valve.
CYLINDER VALVE
HEAD DECK FACE J9109-141
Fig. 8 Grind Valve Seat

SERVICE VALVE SEAT INSTALLATION
Inspect the valve guide bores as described in the
Cleaning and Inspection section of this group. I f i t is
necessary to install valve guides, install the guides
before installing the service seats.
VALVE Replacement valve seat inserts must be installed i f
J9109-140
DEPTH the valve seats have been ground previously. The
illustrated marks indicate valve seats have been
Fig. 7 Valve Depth ground previously.
Grind the valve seats to remove scores, scratches Machine the cylinder head to install the service
and burns. The seat angle should be—Intake 30° and valve seats (Fig. 9) (Fig. 10).
Exhaust 45°. Press service seats into the machined pockets.
Stake the valve seats into the pockets.
BR 5.9L (DIESEL) ENGINE 9 - 169
COMBUSTION COMBUSTION
FACE FACE
VALVE
SEAT
DEPTH
VALVE
SEAT
DEPTH
VALVE SEAT DEPTH VALVE SEAT DEPTH

10.40 ±0.10 mm (0.4094 ±0.004 Inch) 10.20 ±0.10 mm (0.4015 ± 0.004 inch)
VALVE SEAT WIDTH * VALVE SEAT WIDTH

47.0 ±0.013 mm (1.8504 ±0.0005 in) 43.65 ±0.013 mm (1.7185 ± 0.0005 in)
MAXIMUM RADIUS MAXIMUM RADIUS

0.40 mm (0.0157 inch) MAX. 0.40 mm (0.0157 inch) MAX.
SURFACE FINISH SURFACE FINISH

3.2 micrometers (128.0 microinch) 3.2 micrometers (128.0 microinch)
J9409-115 J9409-116
Fig. 9 Machining for Service Valve Seats—Intake Fig. 10 Machining for Service Valve Seats—Exhaust
Valve Valve
SERVICE VALVE SEAT GRINDING
Install the valves in their designated location and
measure the valve depth. The valve depth is the dis
tance from the valve face to the head deck.
Record the depth of each valve (Fig. 11). The depth
is 0.99-1.52 mm (0.039-0.060 inch).
Grind the valve seats to remove scores, scratches
and burns. The valve seat angle is 30° (Intake) and
45° (Exhaust).
Install the valves i n their respective bores and
measure the depth again (Fig. 11). The valve depth MIN. - 0 . 9 9 0 mm ( 0 . 0 3 9 inch)
MAX. - 1.520 mm ( 0 . 0 6 0 inch)
limit is 0.99-1.52 mm (0.039-0.060 inch). Replace the
valve i f the depth is over the limit.
Apply a light coat of valve lapping compound to
each valve and lap each valve to its companion seat. J9109-44
Remove the valves and clean the lapping compound
Fig. 11 Valve Depth with Seat Insert
from the valve and seats.

Measure the valve seat width indicated by the (5) Use a drill, a fine grit Flex-hone and a mixture
lapped surface (Fig. 12). The width limits are 1.5-2.0 of equal parts of mineral spirits and SAE SOW engine
mm (0.060-0.080 inch). I f required, grind lower area oil to de-glaze the bores.
with 60° stone and upper area with 15° stone (Fig. (6) The Crosshatch angle is a function of drill
12). Be sure to center the seat on the valve face. speed and how fast the hone is moved vertically (Fig.
Maintain the valve seat within limits. 14).
(7) Vertical strokes MUST be smooth continuous
MAXIMUM
passes along the full length of the bore (Fig. 14).
J9109-45
Fig, 12 Waive Seat Width

1 STROKE ( f + | ) / P E R S E C O N D
SEiWiCE VALWE SEAT REPLACEMENT
To replace service seat inserts, machine the insert Fig. 14 De-Glazing Drill Speed and Wertical Speed
in the same manner as i f machining out the internal (8) Inspect the bore after 10 strokes.
seat. Hold the same tolerances and follow the same (9) Use a strong solution of hot water and laundry
installation procedures. detergent to clean the bores. Clean the cylinder bores
immediately after de-glazing.
CYLINDER BORES—DE-GLAZE (10) Rinse the bores until the detergent is removed
(1) New piston rings may not seat in glazed cylin and blow the block dry with compressed air.
der bores. (11) Check the bore cleanliness by wiping with a
(2) De-glazing gives the bore the correct surface white, lint free, lightly oiled cloth. I f grit residue is
finish required to seat the rings. The size of the bore still present, repeat the cleaning process until all res
is not changed by proper de-glazing. idue is removed. Wash the bores - and the complete
(3) Cover the lube holes in the top of the block block assembly with solvent and dry with compressed
with waterproof tape. air.
(4) A correctly honed surface will have a cross- (12) Be sure to remove the tape covering the lube
hatch appearance with the lines at 15° to 25° angles holes after the cleaning process is complete.
(Fig. 13). For the rough hone, use 80 grit honing
stones. To finish hone, use 280 grit honing stones. CYLINDER BLOCK REFACING
TOP OF BLOCK
(1) The combustion deck can be refaced twice. The
first reface should be 0.25 mm (0.0098 inch). I f addi
tional refacing is required, an additional 0.25 mm
(0.0098 inch) can be removed. Total allowed refacing
is 0.50 mm (0.0197 inch) - (Fig. 15).
(2) The upper right corner of the rear face of the
block must be stamped with a X when the block is
refaced to 0.25 mm (0.0098 inch). A second X must be
stamped beside the first when the block is refaced to
0.50 mm (0.0197 inch) - (Fig. 16).
(3) Consult the parts catalog for the proper head
Fig. 13 Cylinder Bore Crosshatch Pattern gaskets which must be used with refaced blocks to
ensure proper piston-to-valve clearance.
BR 1.91 (DIESEL) ENGINE 9 - 171
METHOD 1—OVERSIZE BORE

Oversize pistons and rings' are available in two
sizes - 0.50 mm (0.0197 inch) and 1.00 mm (0.0393
inch).
Any combination of standard, 0.50 mm (0.0197
inch) or 1.00 mm (0.0393 inch) overbore may be used
in the same engine.
If more than 1.00 mm (0.0393 inch) overbore is
needed, a repair sleeve can be installed (refer to
Method 2—Repair Sleeve).
Cylinder block bores may be bored twice before use
of a repair sleeve is required (Fig. 17). The first bore
is 0.50 mm (0.0197 inch) oversize. The second bore is
1.00 mm (0.0393 inch) oversize.
After boring to size, use a honing stone to chamfer
the edge of the bore (Fig. 17).
1st REFACE 0.15 mm (0.0058 inch)
2nd REFACE 0.35 mm (0.0138 inch)
BORING AND
® Total 0.50 mm (0.0197 inch) HONING DIAMETERS
® Standard 323.00 mm ±0.10 mm

(12.7165 inch ±0.0039 inch)
1st REFACE 322.85 mm ±0.10 mm
(12.7106 inch ±0.0039 inch)
2nd REFACE 322.50 mm ±0.10 mm
(12.6968 inch ±0.0039 inch)
J9109-118
Fig. 15 Refacing Dimensions of the Cylinder Block
BORING DIAMETER DIMENSION
1st REBORE - 102.469 mm

(4.0342 inch)
2nd REBORE - 102.969 mm
(4.0539 inch)
1st REFACE X
2nd REFACE XX HONING DIAMETER DIMENSIONS
STANDARD 102.020 ± 0.020 mm

(4.0165 ±0.0008 inch)
J9109-116 1st REBORE 102.520 ± 0.020 mm
(4.0362 ± 0.0008 inch)
Fig. 16 Stamp Block after Reface 2nd REBORE 103.020 ± 0.020 mm
(4.0559 ± 0.0008 inch)
CYLINDER BORE REPAll
Cylinder bore(s) can be repaired by one of two CHAMFER DIMENSIONS
methods:
• Method 1:—Over boring and using oversize pis Approx. 1.25 mm (0.049 inch)
tons and rings. by 15°
• Method 2:—Boring and installing a repair sleeve J9109-119
to return the bore to standard dimensions.
Fig. 17 Cylinder Bore Dimensions
9 - 172 5.91 (DIESEL) ENGINE BR
A correctly honed surface will have a Crosshatch
appearance with the lines at 15° to 25° angles with
the top of the cylinder block (Fig. 18). For the rough
hone, use 80 grit honing stones. To finish hone, use
280 grit honing stones.
TOP O F BLOCK
BLOCK REBORE FOR REPAIR SLEEVE
Fig. 18 Crosshatch Pattern of Repaired Sleeve(s) BORE DIA. - 104.500 +0.015 mm

(4.1142 +0.0006 inch)
A maximum of 1.2 micrometer (48 microinch) sur STEP DIM. - 6.35 mm (0.25 inch)
face finish must be obtained.
After finish honing is complete, immediately clean J9109-120
the cylinder bores with a strong solution of laundry
detergent and hot water. Fig. 19 Block Bore for Repair Sleeve Dimensions
After rinsing, blow the block dry.
Check the bore cleanliness by wiping with a white, Wear protective gloves to push the cold sleeve into
lint-free, lightly- oiled cloth. There should be no grit the bore as far as possible.
residue present. Using a sleeve driver, drive the sleeve downward
If the block is not to be used right away, coat it until i t contacts the step at the bottom of the bore
with a rust-preventing compound. (Fig. 20).
METHOD 2—REPAIR SLEEVE

If more than a 1.00 mm (0.03937 inch) diameter
oversize bore is required, the block must be bored
and a repair sleeve installed.
Bore the block cylinder bore to 104.500-104.515
mm (4.1142-4.1148 inch) - (Fig. 19).
Repair sleeves can be replaced by using a boring
bar to bore out the old sleeve. DO NOT cut the cyl
inder bore beyond the oversize limit.
After machining the block for the new repair
sleeve, thoroughly clean the bore of all metal chips,
debris and oil residue before installing the sleeve.
Cool the repair sleeve(s) to a temperature of -12°C
J9109-121
(10°F) or below for a minimum of one hour. Be ready
to install the sleeve immediately after removing i t
from the freezer. Fig. 20 Sleeve Installation
Apply a coat of Loctite 620, or equivalent to the
bore that is to be sleeved.
5.9L (DIESEL) ENGINE 9 - 173
6EHWIC3B P R O C E D U R E S fContinuedf
A sleeve driver can be constructed as follows (Fig. A correctly honed surface will have a Crosshatch
appearance with the lines at 15° to 25° angles with
the top of the cylinder block. For the rough hone, use
80 grit honing stones. To finish hone, use 280 grit
honing stones.
Finished bore inside dimension is 102.020 ±0.020
mm (4.0165 ±0.0008 inch).
A maximum of 1.2 micrometer (48 microinch) sur
face finish must be obtained.
After finish honing is complete, immediately clean
the cylinder bores with a strong solution of laundry
detergent and hot water.
After rinsing, blow the block dry with compressed
air.
HANDLE - STEEL Wipe the bore with a white, lint-free, lightly oiled
cloth. Make sure there is no grit residue present.
A = 127 mm (5 inch) Apply a rust-preventing compound i f the block will
B = 38 mm (1.5 inch) not be used immediately.
C = 6.35 mm (0.25 inch) A standard diameter piston and a piston ring set
D = 25.4 mm (1 inch) must be used with a sleeved cylinder bore.
E = 101 mm (3.976 inch)
F = 107.343 mm (4.226 inch) CAM BORE REPAIR
The front cam bushing bore can be bored to 57.740
J9109-122
Mm ±0.018 mm (2.273 inch ±0.0007 inch) oversize.
Fig. 21 Sleeve Driver Construction DO NOT bore the intermediate or rear cam bore to
the front cam bore oversize dimensions. Intermediate
Set up a boring bar and machine the sleeve to and rear cam bores may be bored to 57.240 mm
101.958 mm (4.014 inch) - (Fig. 22). ±0.018 mm (2.253 inch ±0.0007 inch) oversize.
After removing the boring bar, use a honing stone A surface finish of 2.3 micrometers (92 microinch)
to chamfer the corner of the repair sleeve(s) - (Fig. must be maintained. Not more than 20% of an area
22). of any one bore may be 3.2 micrometers (126 micro-
inch).
Camshaft bores can be repaired individually. I t is
not necessary to repair undamaged cam bores i n
order to repair individually damaged cam bores. The
standard front bushing cannot be used to repair
intermediate or rear bores.
Install all cam bushings flush or below the front
cam bore surface. The oil hole must align to allow a
3.2 mm (0.125 inch) rod to pass through freely (Fig.
23).
SLEEVE DIAMETER - 101.956 mm

(4.014 inch)
SLEEVE PROTRUSION
M I N . - FLUSH WITH BLOCK
MAX. - 0.050 mm (0.0019 inch)
SLEEVE CHAMFER
APPROX. 1.25 mm (0,049 inch)
BY 15° *
J9109-123
Fig. 22 Sleeve Machining Dimensions Fig. 23 Oil Hole Alignment

9 - 174 5.9L (DIESEL) ENGINE - BR
CYLINDER BLOCK CUP PLUG REPLACEMENT

(1) Remove the cup plugs from the oil passages
(Fig. 24).
(2) Apply a bead of Loctite 277 around the outside
diameter of the oil passage cup plugs.
(3) Drive the cup plugs in until they bottom in the
bore (Fig. 24).
(4) Fill the - engine with oil. Run the engine and
check for leaks.
(5) Stop the engine and check the oil level with the
dipstick.
MIN. 68.962 mm (2.715 inch)

MAX. 69.013 mm (2.717 inch)
Out-of-Round - M a x .
0.050 mm (0.002 inch)
Taper - M a x .
0.013 mm (0.0005 inch)
Bearing Clearance - M a x .
0.089 mm (0.0035 inch)
J9109-91
Fig. 24 Cup Plug Locations in Cylinder Block
CONNECTING ROD BEARING AND CRANKSHAFT Fig. 25 Connecting Rod Journal Diameter Limits
JOURNAL CLEARANCE cap. Use clean lubricating oil to coat the inside diam
Measure the connecting rod bore with the bearings eter of the connecting rod bearing shell.
installed and the bolts tightened to 100 N-m (73 ft. (3) Install the bearing shell in the connecting rod
lbs.) torque. cap with the tang of the bearing in the slot to the
Record the smaller diameter. cap. Use clean lubricating oil to coat the inside diam
Measure the diameter of the rod journal at the eter of the bearing shell.
location shown (Fig. 25). Calculate the average diam (4) The four digit number stamped on the connect
eter for each side of the journal. ing rod and cap at the parting line must match and
The clearance is the difference between the con be installed on the oil cooler side of the engine.
necting rod bore (smallest diameter) and the average Install the connecting rod cap and capscrews.
diameter for each side of the crankshaft journal. Tighten the capscrews to 35 N-m (26 ft. lbs.) torque.
If the crankshaft is within limits, replace the bear (5) Use a fine grit stone to remove any burrs from
ing. I f the crankshaft is out of limits, grind the the cylinder block head deck. Zero the dial indicator
crankshaft to the next smaller size and use oversize to the cylinder block head deck.
rod bearings. (6) Move the dial indicator directly over the piston
pin to eliminate any side-to-side movement.
PISTON GRADING PROCEDURE (7) Rotate the crankshaft to top dead center
(1) Install any of the original connecting rod and (TDC). Rotate the crankshaft clockwise and counter
piston assemblies into the No.l cylinder. DO NOT clockwise to find the highest dial indicator reading.
install the piston rings. Record the reading.
(2) Install the upper bearing shell in the connect (8) Remove the piston and connecting rod assem
ing rod with the tang of the bearing in the slot of the bly from the N o . l cylinder and install the assembly
connecting rod. The connecting rod bearing shell into the No.2 cylinder. Repeat the procedure for every
must be installed in the original connecting rod and cylinder using the same piston and connecting rod
assembly.
B R — ^ — — 5.9L (DIESEL) ENGINE 9 - 175
SERVICE PROCEDURES (Continued!
(9) Determine the grade of the piston being used
by referring to the Piston Protrusion Chart (Fig. 26). Rel.
Dimension A Grade
Number
Four digits on top of the piston can be cross refer
enced to a Chrysler part number for replacement 51.554 to 51.607mm 2571 A
(2.029 to 2.031 in)
(Fig. 27). I f the number on the piston cannot be seen,
measure from the top of the piston to the top of the 51.654 to 51.707mm 2572 3
piston pin to see what grade piston is used (Fig. 28). (2.033 to 2.035in)
51.754 to 51.807mm 2573 C
MEASURING USE (2.037 to 2.039in)
PISTON PROTRUSSON GRADE
2571 0.609-0.711 mm (0.024-0.028 in.) A
2571 0.508-0.609 mm (0.020-0.024 in.) B
2571 0.406-0.508 mm (0.016-0.020 in.) C
2572 0.711-0.813 mm (0.028-0.032 in.) A
2572 0 . 6 0 9 - 0 . 7 1 1 mm (0.024-0.028 in.) B
2572 0.508-0.609 mm (0.020-0.024 in.) C
2573 0.813-0.914 mm (0.032-0.036 in.) A

J9509-1
2573 0.711-0.813 mm (0.028-0.032 in.) B
2573 0.609-0.711 mm (0.024-0.028 i n ) C Fig. 28 Piston Grading Measurement

CRANKSHAFT REWORK
Crankshaft main and rod journals may be ground
in increments of 0.25 mm (0.0098 inch) up to a total
of 1.00 mm (0.0394 inch).
J9509-3 The only exception is the main journal thrust
width surface. This journal must be ground in incre
Fig. 26 Piston Protrusion Chart ments of 0.50 mm (0.0197 inch) up to a total of 1.00
mm (0.0394 inch). The thrust surface is located on
the No.6 main bearing. When the thrust surface
requires grinding, the main journal must be ground
to the same undersize dimension.
CAUTION: Welding of the crankshaft is not

allowed. Failure of the crankshaft will result.
MAIM JOURNAL
All main journals are to be ground in the opposite
direction of engine rotation (clockwise as viewed from
the front of crankshaft). Polish the journals in the
same direction as engine rotation.
The main bearing grinding specifications are
J9509-2
shown in (Fig. 29).
Fig. 27 Piston Grading Number Location
9 - 176 5.9L (DIESEL) ENGINE — BR
JOURNAL
STANDARD MAIN JOURNAL DIAMETER
83.000 + 0 . 0 1 3 mm
(3.2677 ±0.0005 inch)
W O R N M A I N JOURNAL DIAMETER LIMIT
82.962 (3.2662 inch)
UNDERSIZES REGRIND TO
0.25 mm 82.750 + 0 . 0 1 3 mm
(0.0098 inch) (3.2579 ± 0 . 0 0 0 5 inch)
0.50 mm 82.500 + 0 . 0 1 3 mm
(0.0197 inch) (3.2480 + 0 . 0 0 0 5 inch)
0.75 mm 82.250 + 0 . 0 1 3 mm
(0.0295 inch) (3.2381 ± 0 . 0 0 0 5 inch)
1.00 mm 82.000 + 0 . 0 1 3 mm
(0.0394 inch) (3.2283 ± 0 . 0 0 0 5 inch)
J9109-128
OUT-OF ROUND & TAPER (MAX.)
0.005 mm (0.0002 inch)
Fig. 31 Crankshaft Thrust Surface
ALL M A I N JOURNALS ARE TO BE PARALLEL
TO THE FRONT A N D REAR M A I N S W I T H I N : PREFERRED PROCEDURE:
0.030 mm (0.001 inch) Smoothly blend a 4.20 ±0.020 mm (0.1654 ±0.0008
J9109-125 inch) radius to the ground diameters (Fig. 32).
ORIGINAL RADIUS
Fig. 29 Crankshaft Main Journal Dimensions
Thrust journals can be ground in the same incre
ments and using the same specifications as all other
main journals. The main journal radius may be
ground using either the preferred or the alternative
procedure providing the thrust surface width is not
being ground. The preferred procedure must be used
when the main bearing thrust width surface is
ground. When the thrust surface width requires
grinding, the main journal must be ground to the
same undersize dimension (Fig. 30).
THRUST JOURNAL WIDTH

37.500 ± 0 . 0 2 5 mm
(1.4764 ± 0 . 0 0 1 inch)
UNDERSIZES REGRIND WIDTH TO
JOURNAL SURFACE
0.50 mm 38.000 ± 0 . 0 2 5 mm
SURFACE FINISH
(0.0197 inch) (1.4961 ± 0 . 0 0 1 inch
1.00 mm 38.500 ± 0 . 0 2 5 mm
© 0.8 micrometer (32.0 microinch)
for a minimum of 4 5 ° into the
(0.0394 inch) (1.5158 ± 0 . 0 0 1 inch) fillet beyond journal surface
J9109-127
® 1.6 micrometer (64.0 microinch)
for remainder of fillet
Fig. 30 Crankshaft Thrust Journal Width
Dimensions © 0.4 micrometer (16.0 microinch)
The thrust surface is to be ground on center within J9109-129

0.10 mm (0.004 inch). I t also must be perpendicular
to the front and rear mains within 0.0015 mm Fig. 32 Grind Crankshaft Main Journal—Preferred
(0.00006 inch) per radial inch on the thrust area Method
(Fig. 31). The surface finish requirement is 0.04
micrometer (16.0 microinch).
BR 5.9L (DIESEI) ENGINE 9 177
S E R V I C E PROCEDURES ( C o n t i n u e d )
CAUTION: DO HOT use the Alternative Procedure
when the thrust surface width is ground, STANDARD ROD JOURNAL DIAMETER
69.000 + 0 . 0 1 3 mm
(2.7165 ± 0 . 0 0 0 5 inch)
ALTERIAIIWE PROCEDURE; W O R N ROD JOURNAL DIAMETER LIMIT
Smoothly blend a 1.25 ±0.020 mm (0.0492 ±0.0008 68.962 (2.7150 inch)
inch) radius to the ground diameters (Fig. 33).
UNDERSIZES REGRIND TO
ORIGINAL RADIUS 0.25 mm 68.750 + 0 . 0 1 3 mm
(0.0098 inch) (2.7067 ± 0 . 0 0 0 5 inch)
0.50 mm 68.500 + 0 . 0 1 3 mm
(0.0197 inch) (2.6969 ± 0 . 0 0 0 5 inch)
0.75 mm 68.250 + 0 . 0 1 3 mm
(0.0295 inch) (2.6870 ± 0 . 0 0 0 5 inch)
1.00 mm 68.000 + 0 . 0 1 3 mm
(0.0394 inch) (2.6772 ± 0 . 0 0 0 5 inch)
OUT-OF ROUND & TAPER (MAX.)

0.005 mm (0.0002 inch)
ALL M A I N JOURNALS ARE TO BE PARALLEL

TO THE FRONT A N D REAR M A I N S W I T H I N :
0.030 mm (0.001 inch)
J9109-126
Fig. 34 Crankshaft Rod Journal Dimensions

ORIGINAL RADIUS
SURFACE FINISH
for a minimum of 45° into the
fillet beyond journal surface
for remainder of fillet
© 0.4 micrometer (16.0 microinch)
WIDTH OF REGRIND/UNDERCUT RADIUS
© 34.5 ± 0.025 mm (1.358 ±0.001 in)
J9109-130
Fig. 33 Grind Crankshaft Main Journai—Alternative

Method
ROD JOURNAL
All rod journals are to be ground in the opposite
JOURNAL SURFACE
direction of engine rotation (clockwise as viewed from
the front of crankshaft). Polish the journals in the SURFACE FINISH
same direction as engine rotation.
The rod bearing grinding specifications are shown 0.8 micrometer (32.0 microinch)
in (Fig. 34). for a minimum of 45° into the
fillet beyond journal surface
1.6 micrometer (64.0 microinch)
PREFERRED PROCEDURE: for remainder of fillet
Smoothly blend a 4.00 ±0.020 (0.1575 ±0.0008 0.4 micrometer (16.0 microinch)
inch) radius to the ground diameters and side faces
(Fig. 35).
J9109-131
Fig. 35 Crankshaft Rod Journal Grind—Preferred

Method
mm
ALTERNATIVE PROCEDURE:
Smoothly blend a 1.25 ±0.020 mm (0.0492 ±0.0008
inch) radius to the ground journals (Fig. 36).
ORIGINAL RADIUS
MAX. 8 3 . 1 0 6 mm (3.2719 inch)
J9109-92
Fig. 37 Crankshaft Main Bearing Bore Diameter
SURFACE FINISH

for a minimum of 45° into the
^ fillet beyond journal surface
v§/ 1.6 micrometer (64.0 microinch)
^ for remainder of fillet
v£/ 0.4 micrometer (16.0 microinch)
WIDTH OF REGRIND/UNDERCUT RADIUS
© 34.79 ±0.025 mm (1.369 ±0.001 in)
J9109-132
Fig, 36 Grind Crankshaft Rod Journai—Alternative

Method
MAIN BEARING CLEARANCE MIN. 8 2 . 9 6 2 mm (3.2662 inch)
Inspect the main bearing bores for damage or MAX. 83.103 mm (3.2682 inch)
abnormal wear.
Install the crankshaft main bearings and measure J9109-93
main bearing bore diameter with the main bolts
tightened to 176 N-m (130 ft. lbs.) torque (Fig. 37). Fig. 38 Crankshaft Main Journal Diameter
Measure the diameter of the main journal at the (2) Position fan to assure clearance for radiator top
locations shown (Fig. 38). Calculate the average tank and hose.
diameter for each side of the journal. (3) Install engine support/lifting fixture.
Calculate the main bearing journal to bearing (4) Raise vehicle on hoist.
clearance, the clearance specifications are 0.119 mm (5) Lift the engine SLIGHTLY and remove the
(0.00475 inch). I f the crankshaft journal is within thru-bolt and nut (Fig. 39).
limits, replace the main bearings. I f not within spec (6) Remove engine support bracket/cushion bolts
ifications, grind the crankshaft to next size and use (Fig. 39). Remove the support bracket/cushion.
oversize bearings.
mswMLLAwmm
(1) With engine raised SLIGHTLY, position the
REMOVAL A N D I N S T A L L A T I O N engine support bracket/cushion to the block. Install
new bolts and tighten to 189 N-m (140 ft. lbs.)
ENGINE FRONT MOUNTS
torque.
REMOVAL
(2) Install the thru-bolt into the engine support
bracket/cushion.
BR — — — — - ^ ^ 5.9L (DIESEL) ENGINE 9 - 179
ENGINE
SUPPORT
BRACKET/
CUSHION
BRACKET J9409-122
Fig. 39 Front Engine Mounts Fig. 40 Positioning Engine Front Mounts

(3) Lower engine with support/lifting fixture while ENGINE REAR MOUNT
guiding the engine bracket/cushion and thru-bolt into
support cushion brackets (Fig. 40). WM0VAI
(4) Install thru-bolt nuts and tighten the nuts to (1) Raise the vehicle on a hoist.
68 N-m (50 ft. lbs.) torque. * (2) Position a transmission jack in place.
(5) Lower the vehicle. (3) Remove support cushion stud nuts (Fig. 41).
(6) Remove lifting fixture. (4) Raise rear of transmission and engine SLIGHTLY.

9 -180 i.11 (DIESEL) ENGINE
HEHOWAi Mm INSTALLATION (Continued)
port cushion.
(6) I f necessary, remove the bolts holding the
INSTALLATION
(1) I f removed, position the transmission support
bracket to the transmission. Install new attaching
(2) Position support cushion to transmission sup
port bracket. Install stud nuts and tighten to 47 N-m
(3) Using the transmission jack, lower the trans
mission and support cushion onto the crossmember
(Fig. 41).
(4) Install the support cushion bolts and tighten to
(5) Remove the transmission jack.
ENGINE ASSEMBLY
Fig. 42 Generator Removal
REMOVAL
(3) Remove the upper crossmember and top core
support.
equipped (refer to Group 24, Heating and Air Condi
tioning for service procedures).
Cooling System).
(7) Remove the A/C compressor with the lines Fig, 43 Heater Hoses
(8) I f equipped, remove the condenser. (20) Disconnect the intercooler inlet duct from the
(9) Remove the washer bottle. turbocharger and the intercooler. Remove the Inlet
duct.
(10) Remove the radiator overflow bottle.
(11) Disconnect the top radiator hose. (21) Disconnect the intercooler outlet duct from
the air inlet housing and the intercooler. Remove the
(12) Remove the fan.
outlet duct.
(13) Remove the fan shroud.
(14) Disconnect the lower radiator hose. (22) Disconnect the accelerator linkage, the speed
(15) Remove radiator (refer to Group 7, Cooling control linkage and the throttle valve linkage.
System). (23) Disconnect the power steering hoses, i f
(16) Remove the generator (Fig. 42) with the wire equipped,
connections (refer to Group 8B, Battery/Starter/Gen (24) Disconnect the transmission cooler lines.
erator Service). (25) Disconnect all electrical connections from the
(17) Disconnect the heater hoses at the dash panel engine. Put tags on the connections to identify their
and at the water valve (Fig. 43). locations.
(18) Disconnect the air inlet tube from the turbo (26) Disconnect the fuel lines to the lift pump and
charger (Fig. 44) and the air intake housing. Remove fuel return. Use tags to identify the lines.
the tube. (27) On. Manual Transmission vehicles, remove the
(19) Remove the exhaust pipe from the turbo shift lever (refer to Group 21, Transmissions).
charger outlet flange (Fig. 44). (28) Raise and support the vehicle on a hoist.
5,91 (DIESEL) ENGINE 9 - 181
sion installation.
(8) Install the dust shield and transmission cover.
(9) Install the prop shaft (refer to Group 16, Pro
peller Shaft).
(10) Install the starter motor (refer to Group 8B,
Battery/Starter/Generator Service). Connect the starter
wires.
(11) Install the transmission cooler line brackets to
oil pan.
(12) Install and tighten engine front mount thru-
bolt nuts.
(13) Install the oil pan. Install the drain plug.
(15) On Manual Transmission vehicles, install the
shift lever (refer to Group 21, Transmissions).
(16) Connect the fuel lines to the lift pump and
fuel return. Use tags to identify the lines.
(17) Connect all electrical connections to the
engine. Use tags to identify their locations.
Fig. 44 Air inlet Tube and Exhaust Pipe Connection
(20) Connect the accelerator linkage, the speed
(29) Drain the engine lubricating oil. Dispose of control linkage and the throttle valve linkage.
the oil according to all applicable regulations. (21) Install the outlet duct. Connect the intercooler
(30) Remove the oil pan. outlet duct to the air inlet housing and the intercooler.
(31) Remove engine front mount thru-bolt nuts. (22) Install the inlet duct. Connect the intercooler
(32) Remove the transmission cooler line brackets inlet duct to the turbocharger and the intercooler.
from oil pan. (23) Install the exhaust pipe to the turbocharger
(38) Disconnect exhaust pipe at manifold. outlet flange.
(34) Disconnect the starter wires. Remove starter (24) Install the air inlet tube. Connect the air inlet
motor (refer to Group 8B, Battery/Starter/Generator tube to the turbocharger and the air intake housing.
Service). (25) Connect the heater hoses at the dash panel
(35) Remove the dust shield and transmission and at the water valve.
cover. (26) Install the generator and wire connections
(36) Refer to Group 21, Transmissions for trans (refer to Group 8B, Battery/Starter/Generator Ser
mission removal. vice).
(37) Lower the vehicle. (27) Install the radiator (refer to Group 7, Cooling
(38) Put a cover or tape over all engine openings. System).
(39) Lift the engine out of the vehicle. (28) Connect the lower radiator hose.
(40) Install the engine on a suitable stand. (29) Install the fan shroud.
(41) Remove all accessories and brackets not pre (30) Install the fan.
viously removed for use with the replacement engine. (31) Connect the top radiator hose.
(32) Install the radiator overflow bottle.
INSTALLATION (33) Install the washer bottle.
(1) Check the data,plate to verify that the replace (34) I f equipped, install the condenser.
ment . engine is the same model and rating as the (35) Install the A/C compressor with the lines
engine that was removed. attached.
(2) Install all accessories and brackets that had (36) Evacuate and charge the air conditioning sys
been removed from the previous engine. tem, i f equipped (refer to Group 24, Heating and Air
(3) Use the lifting brackets to lift the engine off of Conditioning for service procedures).
the stand. (37) Install the transmission oil cooler.
(4) Position the engine in the chassis with the (38) Install the upper crossmember and top core
thru-bolt installed. support.
(5) Remove the covers or tape covering the engine (39) Install the serpentine belt (refer to Group 7,
openings. Cooling System).

(40) Fill the cooling system with a mixture of 50% • Step 2—Tighten the bolts, in sequence (Fig. 46), to
water and 50% ethylene-glycol base antifreeze (refer 120 N-m (89 ft. lbs.) torque. Check the torque. I f lower
Group 7, Cooling System for the proper procedure). than 120 N-m (89 ft. lbs.), tighten to this torque.
(41) Fill the engine with the required amount of • Step 3—Tighten the bolts, in sequence (Fig. 46),
clean engine lubricating oil (refer to Group 0, Lubri an additional 90°.
cation and Maintenance).
(42) install the battery and connect the battery C = * FRONT
cables.
(43) Check the oil level after the engine has run
for 2 or 3 minutes. Oil held in the oil filter and oil
passages will cause the oil level in the pan to be
lower than normal for a short period of time.
(44) Operate the engine at idle for 5 to 10 minutes
and check for leaks and loose parts.
ROCIER LEWERS IND PUSH iODS J9109-32

Fig. 46 Rocker Lever (Head Botts) Tightening
REMOVAL
Sequence
(1) Remove the valve covers.
(2) Loosen the adjusting screw locknuts. Loosen (5) Tighten the 8 mm bolts to 24 N-m (18 ft. lbs.)
the adjusting screws until they stop (Fig. 45). torque.
(3) Remove the bolts from the rocker lever pedes (6) Install the valve cover. Tighten the valve cover
tals. Remove the pedestals and rocker lever assem bolt to 24 N-m (18 ft. lbs.) torque.
blies (Fig. 45).
(4) Remove the push rods. The rear two push rods CYLINDER HEAD
must be raised through holes in cab overhang. These cylinder heads can only be used on engines
with an intercooler. DO NOT interchange with ear
LOCKNUT ADJUSTING lier models.
REMOVAL .
(1) Drain the coolant. DO NOT waste reusable
coolant. I f the solution is clean, drain the coolant into
a clean container for reuse.
(2) Drain the engine oil. Dispose of the used oil
properly.
(3) Disconnect the radiator and heater hoses (refer
to Group 7, Cooling System).
(4) Remove the turbocharger.
(5) Remove the exhaust manifold (Fig. 47).
J9109-31
Fig. 45 Location of Rocker Lever Components

INSTALLATION
(1) Make sure the dowel rings in the pedestals are
installed into the dowel bores in the cylinder head.
(2) I f the push rod is holding pedestal off head, bar
the engine until the pedestal will set on the head
surface without interference.
(3) Use clean engine oil to lubricate the cylinder
head bolt threads and under the bolt heads.
(4) Install the long bolts (12 mm) into the rocker
lever pedestals. Tighten the bolts as follows:
• Step 1—Tighten the bolts, in sequence (Fig. 46),
to 90 N-m (66 ft. lbs.) torque. Check the torque. I f
lower than 90 N-m (66 ft. lbs.), tighten to this torque. Fig. 47 Exhaust Manifold
HEH®WAL AN© I N S T A L L A T I O N (Continued)
(6) Remove the fuel lines and injector nozzles INSTALLATION
(refer to Group 14, Fuel System). (1) The cylinder block and head must be clean and
(7) Remove the valve covers. dry.
(8) Remove the rocker levers and push rods. (2) Position the gasket onto the dowels (Fig. 50).
(9) Remove the fuel filter/water separator (Fig. 48). Make sure the gasket is correctly aligned with the
Refer to Group 14, Fuel System, for the proper pro holes in the cylinder block.
cedures. Remove the remote fuel filter/water separa (3) Carefully put the cylinder head onto the gasket
tor head. and cylinder block. Make sure the cylinder head Is
installed onto the dowels in the cylinder block (Fig. 50).
FUEL TEMPERATURE SENSOR
CYLINDER HEAD
Fig. 50 Cylinder Head/Gasket Alignment

(4) Install the push rods and rocker levers.
(5) Use clean engine oil to lubricate the cylinder
head bolt threads and under the bolt heads.
(6) The cylinder head bolts are 3 different sizes.
Fig. 48 FuelAfVater Separator Filter Install the bolts in the proper hole. Tighten the bolts
as follows:
(10) I f the engine is hot, remove the cylinder head • Step 1—Tighten all bolts, i n sequence (Fig. 10),
bolts in the sequence shown in (Fig. 49). The removal to 90 N-m (66 ft. lbs.) torque. Check the torque. I f
sequence is not important i f the engine is cold. There lower than 90 N-m (66 ft. lbs.), tighten to this torque.
are 3 sizes of head bolts. Note the position of each • Step 2—Tighten all long 12 mm bolts (Nos. 4, 5,
bolt for future Installation. 12, 13, 20 and 21), in sequence (Fig. 51), to 120 N-m
(11) Remove the cylinder head and gasket from the (89 ft. lbs.) torque. Check the torque. I f lower than
cylinder block. 120 N-m (89 ft. lbs.), tighten to this torque.
• Step 3—Tighten all bolts, in sequence (Fig. 51),
an additional 90°.
J9109-36
Fig. 49 Cylinder Head Bolt Removal Sequence-

J9109-3
Cylinder Head Hot
Fig. 51 Cylinder Head Tightening Sequence
(7) Be sure to lubricate the push rod sockets with (2) Install the valve stem seals (Fig. 53). The
clean engine oil. Be sure push rod is seated properly intake and exhaust valve seals are the same.
in the tappet.
(8) Install the rocker lever pedestal bolts and
(9) Adjust the valve clearance.
(10) Install the valve covers. Tighten the bolts to
2 4 N-m (18 ft. lbs.) torque.
(11) Install the Injector nozzles and fuel lines
(refer to Group 14, Fuel System).
(12) Install the remote fuel filter/water separator
head. Install the fuel filter/water separator (refer to
Group 14, Fuel System for the proper procedures).
(13) Install the exhaust manifold (refer to Group
11, Exhaust System and Intake Manifold). Fig. 53 Valve Stem Seal Installation
(14) Install the turbocharger.
(3) Lubricate the stems with SAE 90W oil before
(15) Connect the radiator and heater hoses.
installing the valves. Install the valves in the same
(16) Fill the engine with new coolant or the clean
positions as removed.
drained coolant (refer to Group 7, Cooling System for
(4) Compress the valve spring after installing the
the proper procedure).
spring and retainer (Fig. 54).
(17) Fill the engine with clean lubricating oil (refer
(5) Install new valve collets and release the spring
to Group 0, Lubrication and Maintenance).
tension (Fig. 54).
WALWES AND WALWE SPRINGS COLLETS VALVE
REMOVAL
(1) Remove the cylinder head.
(2) Mark the valves to identify their position.
(3) Compress the valve spring and remove the
valve stem collets (Fig. 52).
(4) Release valve spring and remove the retainer
and spring (Fig. 52).
(5) Remove the remaining collets, retainers,
springs and valves. Keep the valves in a labeled rack.
(6) Remove the valve stem seals (Fig. 52).
Fig. 54 Valve, Valve Spring and Collet Installation

WARNING: WEAR PROTECTIVE EQUIPMENT AND
DO NOT STAND IN LINE WITH THE VALVE STEM
WHEN TAPPING THE VALVES.
(6) Tap the ends of the valve stems with a mallet

to verify the collets are seated.
(8) Check the valve clearance adjustment.
GEAR HOUSING COWER
Fig. 52 Valve Removal REMOVAL

(1) Remove fan drive assembly.
INSTALLATION (2) Remove the fan belt (Fig. 55).
(1) Clean all cylinder head components before (3) Remove belt tensioner (Fig. 55).
assembling. (4) Remove oil fill tube and adaptor (Fig. 56).
B R — — _ _ _ _ 5.9L (DIESEL) ENGINE 9 - 185

INSTALLATION
(1) Lubricate the front gear train with clean
engine oil.
(2) Thoroughly clean the front seal area of the
crankshaft. The seal lip and the sealing surface on
the crankshaft must be free from all oil residue to
prevent seal leaks.
(3) Install the gear housing cover and a new gas
ket.
(4) Install the bolts but DO NOT tighten them at
this time.
(5) Use the alignment/installation tool from the
seal kit to align the cover to the crankshaft (Fig. 58).
Fig. 55 Drive Beit Installation
Fig. 58 Alignment/Installation Tool

(6) Tighten the gear housing cover bolts to 24 N-m
(7) Remove the alignment/installation tool. Always
Fig. 56 Oil Fill Tube use a seal pilot when you install a seal.
(5) Remove vibration damper. (8) Apply a bead of Loctite 277 to the outside
(6) Remove the bolts that hold the gear cover to diameter of the seal. Install the pilot from the seal
the gear housing. • kit onto the crankshaft. Install the seal onto the pilot
(7) Gently pry the cover away from the housing, and start into the gear housing cover. Remove the
taking care not to mar the gasket surfaces (Fig. 57). pilot.
(8) Clean the old gasket residue from the back of (9) Use the alignment/installation tool and a plas
the gear cover and front of the gear housing. tic hammer to install the seal to the correct depth. To
prevent damage to the seal carrier, hit the align
ment/installation tool alternately at the 12, 3, 6 and
9 o'clock positions.
(10) Install the oil fill tube and mounting bolts.
Tighten the bolts to 43 N-m (32 ft. lbs.) torque.
(11) Install the vibration damper. DO NOT tighten
the bolts to the correct torque valve at this time.
(12) Install the belt tensioner. Tighten the mount
ing bolts to 43 N-m (32 ft. lbs.) torque.
(13) Raise the belt tensioner to install the belt.
(14) Tighten the vibration damper bolts to 125
N-m (92 ft. lbs.) torque. Use an engine barring tool to
keep the engine from rotating during tightening
operation.
GEAR HOUSING
Fig. 57 Gear Housing and Cover REMOVAL
(1) Remove the engine assembly from the vehicle.

(2) Remove the front end components and the gear (4) Install the following:
housing cover (refer to Gear Housing Cover Removal • Fan hub assembly (refer to Group 7, Cooling
for the proper procedures). System)
(3) Remove the following: • Fuel injection pump (refer to Group 14, Fuel
• Camshaft System) 4
• Gear driven accessories • Gear driven accessories

• Fuel injection pump (refer to Group 14, Fuel (5) Install the gear housing cover (refer to Gear
System) Housing Cover Installation for the proper proce
• Fan hub assembly (refer to Group 7, Cooling dures).
System) (6) Install the front end components.
(4) Remove the gear housing and gasket (Fig. 59). (7) Install the engine assembly into the vehicle.
(5) Clean the gasket material from the cylinder
block. TIMING PIN
The timing pin can be replaced without removing
GEAR the assembly from the gear housing.
HOUSING
REMOVAL
(1) Remove the timing pin by prying the retaining
ring out with a small screwdriver. Replace the retain
ing ring i f i t is damaged during removal.
INSTALLATION
(1) I f timing pin assembly is removed from gear
housing, i t must be precisely reset to obtain exact
TDC.
(2) Install a new O-Ring, lubricate the pin and
position i n the housing (Fig. 61). Install the new
retaining ring to 1.5 mm (0.059 inch).
J9109-103
CAMSHAFT
Fig. 59 Gear Housing/Gasket GEAR
INSTALLATION O-RING
(1) Install a new gasket and the gear housing. ENGINE
Tighten the bolts to 24 N-m (18 ft. lbs.) torque. TIMING PIN
(2) Install the camshaft. Make sure the alignment
marks on the camshaft and crankshaft gears are
aligned (Fig. 60).
RETAINER
RING
g j " 1.5 mm (0.059 inch)

GEAR HOUSING
J9109-46
Fig. 61 Engine Timing Pin Location

TIMING PIN HOUSING ASSEMBLY
REMOVAL
(1) Locate TDC for cylinder No.l.
(2) Remove the timing pin housing assembly and
gasket.
J9109-104 (3) Clean any gasket material from the gear hous
ing and from the timing pin housing assembly.
Fig. 60 Camshaft/Crankshaft Gear Aiignment
(3) I f a new housing is installed, the timing pin INSTALLATION—CYLINDER HEAD ON
assembly must be accurately located. The location of the timing pin assembly on the
gear housing is critical for correct engine adjustment.
5 J L (DSESEL) ENGINE I - 187
Follow this procedure to install the assembly so that
it corresponds to TDC for cylinder No.l.
(1) Look through the hole in the gear housing and
rotate the engine until the hole in the cam gear can
be seen.
(2) Remove the injector nozzles from all of the cyl
inders. This step is important to vent the cylinders so •
the crankshaft can be rotated smoothly to locate TDC
for cylinder No.l.
(3) Temporarily install the vibration damper.
(4) Fabricate and install a wire pointer (Fig. 62).
This can be done by forming a piece of wire that can
be tighten under one of the gear housing capscrews.
The wire should extend from the gear cover to a
place on the crankshaft vibration damper that is eas
ily seen.
Fig. 63 Locate and Mark Vibration Damper—First
Mark
Fig. 62 Fabricated Wire Pointer 'J9409-119

(5) Rotate the crankshaft one-quarter rotation in
the direction of engine rotation. Fig. 64 Mark Vibration Damper—Second Mark
(6) Tighten the adjusting screw for the No.l intake (11) Measure the distance and mark the vibration
valve to zero lash plus 5 turns. damper at one-half that distance between the two
marks. This mark is the TDC mark (Fig. 65).
CAUTION: Use extreme care when rotating the
crankshaft. Use of too much force could damage
the valve or push rod (Fig. 63).
(7) Rotate the crankshaft slowly in the opposite

direction of normal engine rotation until the piston
touches the intake valve (Fig. 63).
(8) Mark the vibration damper at the wire pointer
(Fig. 63).
(9) Rotate the crankshaft in the direction of nor
mal engine rotation until the piston touches the
intake valve (Fig. 64). Make sure that the piston
touches the intake valve with approximately
Fig. 65 Location of Top Dead Center (TDC)
the same amount of force as in the previous
step (Fig. 64). (12) Completely loosen the intake valve adjusting
(10) Mark the vibration damper at the wire screw. I f not done, damage to the intake valve or
pointer (Fig. 64). push rod could occur when the crankshaft is rotated.
i?EH©WAL im® INSTALLATION (Continued)
(13) 'Rotate the crankshaft in the direction of nor
mal engine rotation until the pointer is aligned with
the TDC mark. Rotate crankshaft one additional
turn.
(14) The timing pin hole in the cam gear should be
visible or felt through the back side of the gear hous
ing. I f not, the crankshaft must be rotated one revo
lution in the direction of engine rotation.
(15) Apply a coat of Loctite® 59241 (Liquid
Teflon), or equivalent to the threads of the Torx head
bolts. Install the timing pin assembly and new
O-ring.
(16) Hold the timing pin in the hole to align the 50.8 mm
housing and install the Torx head bolts. Tighten the
Torx bolts to 5 N-m (44 in. lbs.) torque.
(17) Install the remaining rocker lever pedestal
assemblies. Tighten the rocker lever pedestal mount Fig. 67 Fabricated Steel Plate
ing capscrews.
(18) Adjust the valves.
(19) Install the injectors and bleed the fuel system
(refer to Group 14, Fuel System).
(20) Install the fuel pump (refer to Group 14, Fuel
System). •
(21) Install the gear cover.
(22) Remove the pointer. Install the crankshaft
vibration, damper.
INSTALLATION—CYLINDER HEAD REMOVED

The timing pin assembly is precisely located on the
gear housing to correspond to TDC for Cylinder No.l. Fig, 68 Fabricated Plate Location on NoJ Cylinder
The timing pin assembly must be relocated i f the
gear housing is interchanged. (4) Rotate the crankshaft In the direction of rota
(1) Temporarily install the vibration damper and a tion until the piston contacts the plate.
fabricated wire pointer (Fig. 66). Put a flat washer (5) Mark the vibration damper (Fig. 65).
between the pointer and gear housing to prevent (6) Rotate the engine in the opposite direction
damage to the gear housing. until the piston contacts the plate.
(7) Mark the vibration damper (Fig. 65).
(8) Mark the vibration damper for TDC. TDC will
be one-half the distance between the first two marks
(Fig. 65).
(9) Remove the plate and rotate the engine In the
direction of rotation until the pointer aligns with the
TDC mark.
(10) Look for the timing pin hole in the camshaft
gear. I f i t is not visible, rotate the crankshaft one
complete rotation. Align the pointer with the TDC
mark.
(11) Install the timing pin housing assembly with
a new gasket.
(12) Apply a coat of Loctite 59241 liquid teflon, or
equivalent to the threads of the torx head bolts.
(13) Push the pin into the hole in the cam gear to
align the timing pin housing.
Fig, 68 Fabricated Wire Pointer (14) Hold the pin in while tightening the torx head
(2) Fabricate a steel plate (Fig. 67). bolts to 5 N-m (44 In. lbs.) torque. Be sure timing pin
(3) Use two flywheel housing bolts to assemble the is disengaged before rotating the engine.
plate over No.l cylinder (Fig. 68). (15) Remove the vibration damper and wire pointer.
BR 5 JL (DIESEL) ENIiNE I - 189
R E i O W L MiB INSTALLATION fContinued)
CAMSHAFT (6) Remove the camshaft, gear and thrust plate.
REMOVAL
(1) Remove the following parts:
• Valve covers
© Rocker lever assemblies
@ Push rods
© Drive belt
• Fan hub assembly
• Vibration damper
© Gear housing cover
© Lift pump
(2) Insert the dowels through the push tube holes
and Into the top of each tappet. When properly
installed, the dowels can be used to pull the tappets
up (Fig. 69).
(3) Pull the tappets up and wrap a rubber band Fig. 71 Thrust Plate Bolt Location
around the top of the dowel rods (Fig. 69). This will BUSHING REPLACEMENT
prevent the tappets from dropping down. (1) Measure the diameter of each bore. (The limit
DOWEL TOOL for the bushing in the No.l bore is the same as for
the other bores without bushings). The limit of the
inside diameter is 54.133 mm (2.1312 inch). I f the
camshaft bore for the first cam bushing is worn
beyond the limit, install a new service bushing.
Inspect the rest of the camshaft bores for damage or
excessive wear.
(2) I f the bores without a bushing are worn beyond
the limit, the engine must be removed for machining
and installation of service bushings, i f badly worn,
replace the cylinder block. *
(3) Remove the bushing from the No.l bore, using
a universal cam bushing tool.
(4) Mark the cylinder block so you can align the oil
hole in the cylinder block with the oil hole in the bush
ing.
Fig. 69 Holding Tappets in Place
Apply a coating of loctite® 6 0 9 to the backside of the
(4) Rotate the crankshaft to align the crankshaft new bushing. Avoid getting loctite® in the oil hole.
to camshaft timing marks. (Fig. 70) (5) Use a universal cam bushing installation tool
and Install the bushing so that i t is even with the
front face of the cylinder block. The oil hole must be
aligned. A 3.2 mm (0.128 inch) diameter rod must be
able to pass through the hole (Fig. 72).
(6) Measure the installed bushing. The limit of the
inside diameter is 54.133 mm (2.1312 inch).
J9109-51
Fig. 70 Align Crankshaft to Camshaft

(5) Remove the bolts from the thrust plate (Fig. 71). Fig. 72 Oii Hole Alignment
i - 190 5.9L (DIESEL) E N G I N E BR
G E A R REPLACEMENT
(1) Press the camshaft out of the gear.
(2) Remove all burrs and smooth any rough sur
faces caused by removing the gear.
(3) Install the camshaft key.
(4) Lubricate the camshaft surface with Lubriplate
105, or equivalent.
CAUTION: The camshaft gear will be permanently

distorted if overheated. The oven temperature
should never exceed 177°C (350°F).
(5) Heat the gear in an oven at 177°C (350°F) for

45 minutes.
WARNING: WEAR PROTECTIVE G L O V E S TO HAN BACKLASH - 0 . 0 8 0 - 0 . 3 3 0 mm

D L E THE HOT G E A R . ( 0 . 0 0 3 - 0 . 0 1 3 inch)
CLEARANCE - C U 5 2 - 0 . 2 5 4 mm
(6) Install the gear with the timing marks visible. ( 0 . 0 0 6 - 0 . 0 1 0 inch)
Be sure the gear is seated against the camshaft
shoulder. Fig. 73 Camshaft Backiash and End Clearance
(7) I f the camshaft is not to be used immediately, TAPPET
lubricate the lobes and journals to prevent rust.
REMOVAL
INSTALLATION (1) Remove the camshaft.
(1) Apply a coat of Lubriplate 105 to the camshaft (2) Insert a trough the full length of the cam bore
bores. (Fig. 74). Cummins Tappet Changing Tool 3822513 is
(2) Lubricate the camshaft lobes, journals and available for this job.
thrust washer with Lubriplate 105, or equivalent. (3) Make sure the trough is positioned so i t will
catch the tappet when the wooden dowel is removed.
CAUTION: When installing the camshaft, DO NOT
(4) Identify the location of each tappet as it is
push it in farther than it will go with the thrust
removed. The tappets must be installed in their orig
washer in place. Pushing it too far can dislodge the
inal locations.
plug in the rear of the camshaft bore and cause an
(5) Only remove one tappet at a time. Remove the
oil leak.
rubber band from the two companion tappets, secur
ing the tappet not to be removed with the rubber
(3) Install the camshaft/thrust washer. Align the
band.
timing marks as illustrated (Fig. 70).
(6) Pull the wooden dowel from the tappet bore
(4) Install the thrust washer bolts and tighten to
allowing the tappet to fall into the trough (Fig. 74).
(7) Normally the tappet will fall over when i t
(5) Verify the camshaft has the correct amount of
drops into the trough. Use a flashlight to determine
backlash and end clearance (Fig. 73).
this. I f the tappet does not fall over, shake the trough
(6) Install the following parts:
gently to get it to do so.
• Lift pump
(8) Special care should be taken, when removing
• Gear housing cover
the No.6 cylinder tappets. DO NOT knock or shake
• Vibration damper
the tappet over the end barrier of the trough.
• Fan hub assembly
(9) Carefully pull the trough and tappet from the
• Drive belt
cam bore and remove the tappet. Repeat the process
• Push rods
until all tappets are removed.
• Rocker lever assemblies
• Valve covers INSTALLATION
(7) Install the engine in the vehicle. (1) Insert the trough the full length of the cam
(8) Operate the engine at idle for five to ten min bore.
utes and check for leaks and loose parts. (2) Feed the installation tool down the tappet bore
and into the trough (Fig. 75).
(3) Feed the installation tool cord through the cam
bores. Carefully pull the trough and installation tool
5.9L (DIESEL) ENGINE I -191
R E M O V A L AMB INSTALLATION (Continued!
TROUGH
TAPPET
J9109-55 J9109-155"
Fig. 74 Tappet Removal using a Trough Fig. 76 insert installation Tool into Tappet
TAPPET
AND
TOOL
J9109-153 J9109-154
Fig. 75 Tappet Installation Tool Fig, 77 Pull Tappet/Tool into Position

out the front. The barrier at the rear of the trough (10) Remove the Installation tool from the tappet.
will assure the tool will be pulled out with I t . ' (11) install a wooden dowel into the top of the tap
(4) Lubricate the tappets with Lubriplate 105, or pet and secure i t with a rubber band.
equivalent. (12) Repeat this process until all tappets have
(5) Insert the Installation tool into the tappet (Fig. been Installed.
76). To aid in removing the installation tool after the (13) Install the camshaft.
tappets is Installed, work the tool in and out of the
tappet several times before installing the tappets. OIL PAN AND SUCTION TUBE
(6) Place the tappet and tool in the trough and
slide the trough back Into the cam bore (Fig. 76). REMOVAL
(7) Pull the tool/tappet through the cam bore and (1) Disconnect the negative cable from the battery.
up Into the tappet bore (Fig. 77). (2) Remove transmission from vehicle, refer to
(8) Difficulty could be experienced in getting the Group 21 Transmission and Transfer Case.
tappet to make the bend from the trough up to the (3) Remove flywheel ring gear assembly.
tappet bore (due to the webbing of the block). I f this (4) Disconnect starter cables from starter motor.
occurs, pull the trough out enough to allow the tap (5) Remove transmission oil cooler bolts.
pet to drop down and align itself. Now pull the tap (6) Remove starter motor and spacer plate assem-
pet up Into the bore carefully. bly.
(9) After the tappet has been pulled up into posi
tion, slide the trough back into the cam bore and WARNING: HOT OIL CAN CAUSE PERSONAL INJURY.
rotate i t 1/2 turn. This will position the round side of
the trough up, which will hold the tappet in place.
9 - 192 5 J L (DIESEL) ENGINE BR
(7) Drain the used engine oil. Dispose of the used (4) I f the cylinder bores have ridges, use a ridge
oil properly. reamer to cut the ridge from the top of the cylinder
(8) Remove oil pan bolts, lower pan slightly and bore before removing the piston. Make sure the ridge
remove oil suction tube. reamer does not make a deep cut into the bore. DO
(9) Remove oil pan. NOT remove more metal than is necessary to remove
the ridge.
GASKET
(5) I f cylinders have ridges, the cylinders are over
size and will need boring.
(6) Use a hammer and a steel stamp to mark the
cylinder number onto each connecting rod cap. Mark
the cylinder number onto the top of each piston.
(7) Remove the connecting rod bolts and rod caps.
Use care so the cylinder bores and connecting rods
are not damaged.
(8) Use a hammer handle or similar object to push
the piston and connecting rod through the cylinder
bore.
(9) Store the piston/rod assemblies in a rack.
(10) I f a piston must be replaced, replace with the
same part number (grading) that was removed.
INSTALLATION
(1) Lubricate the cylinder bore with clean engine
oil.
(2) Generously lubricate the rings and piston
skirts with clean engine oil.
(3) Compress the rings using a piston ring com
Fig, 78 Oii Pan, Suction Tube and Gasket pressor tool (Fig. 79). I f using a strap-type ring com
INSTALLATION pressor, make sure the inside end of the strap does
(1) Clean the sealing surface. not hook on a ring gap and break the ring.
(2) Install the suction tube and gasket. Tighten
(3) Fill the joint between the pan rail/gear housing
and pan rail/rear cover with sealant. Use Three Bond
1207-C, or equivalent.
(4) Install the pan and gasket (Fig. 78). Tighten
the bolts to 24 N-m (18 ft. lbs.) torque. PISTON
(5) Install the drain plug with a new sealing RING
washer and tighten to 80 N-m (60 ft. lbs.) torque.
(6) Fill the engine with clean lubrication oil. Run COMPRESSOR TOOL J9] 09-83
the engine and check for leaks. Fig. 79 Piston Ring Compressor Tool
(7) Stop the engine and let It set for five minutes.
Check the oil level, and add oil i f needed. (4) Bar the crankshaft so the rod journal for the
piston to be installed is at BDC (Bottom Dead Cen
PISTON IND CONNECTING iOD ASSEMBLY ter) - (Fig. 80).
The turbocharged intercooler piston has a Ni-Re- (5) Be sure the FRONT marking on the piston and
sist Insert with a keystone profile for the top com the numbers on the rod and cap are oriented as illus
pression ring. The new piston has a new design bowl trated.
and a 7 mm longer piston pin. These pistons can not (6) Position the piston and rod assembly into the
be interchanged with earlier models. cylinder bore with the word FRONT on the piston
towards the front of the cylinder block. Use care
REMOVAL when you install the piston and connecting rod so the
(1) Remove the engine assembly from the vehicle. cylinder bore is not damaged.
(2) Remove the cylinder head from the block. (7) Push the piston into the bore until the top of
(3) Remove the oil pan and suction pump. the piston is approximately 50 mm (2 inch) below the
J9109-86
SIDE CLEARANCE LIMITS

MIN. 0 . 1 0 0 mm ( 0 . 0 0 4 inch)
MAX 0 . 3 0 0 mm ( 0 . 0 1 2 inch)
J9109-84
Fig. 80 Piston/Rod Assembly at BDC Fig. 82 Side Ciearance between Connecting

Rod/Crankshaft
top of the block. Carefully pull the connecting rod
onto the crankshaft journal. (13) Install the suction tube and oil pan.
(8) Use clean engine oil to lubricate the threads (14) Install the cylinder head onto the block.
and under the heads of the connecting rod bolts. (15) Install the engine assembly into the vehicle.
(9) The 4 digit number stamped on the rod cap at
the parting line must match and be installed towards CRANKSHAFT
the oil cooler side of the engine (Fig. 81).
REMOVAL
(1) Remove the rear crankshaft seal housing.
(2) Remove the gear housing.
(3) Rotate the engine to a horizontal position and
remove the main bearing bolts.
(4) The main bearing caps should be numbered. If
they are not, be sure to mark them, beginning with
number one at the front and ending with number
seven at the rear (Fig. 83).
J9109-85 MAIN
BEARING
CAP
Fig. 81 Correct Rod Cap Installation
(10) Install the rod cap and bolts to the connecting
rod. Tighten the connecting rod and bolt evenly in 3
steps.
• Tighten the bolts to 35 N-m (26 ft. lbs.) torque.
(11) The crankshaft must rotate freely. Check for
freedom of rotation as the caps are installed. If the
crankshaft does not rotate freely, check the installa
tion of the rod bearing and the bearing size. J9109-87
(12) Measure the side clearance between the con
necting rod and the crankshaft (Fig. 82). DO NOT Fig. 83 Numbering Main Bearing Caps
measure the clearance between the cap and crank CAUTION: DO NOT pry on the main caps to free
shaft. them from the cylinder block.
(5) Use two of the main bearing cap bolts to wiggle
the main cap loose, being careful not to damage the
bolt threads (Fig. 84). Remove the caps.
Fig. 86 Piston Cooling Nozzles

(3) Install the combination thrust/main bearing in
the number six main bearing location.
(4) Lubricate the bearings with Lubriplate 105, or
equivalent.
WARNING: TO AVOID INJURY, USE A HOIST TO

Fig. 84 Main Bearing Cap Removal INSTALL THE CRANKSHAFT.
WARNING: USE A HOIST TO AVOID INJURY.
(5) Install the crankshaft.
(6) Lift the crankshaft and gear from the cylinder
CAUTION: Crankshaft must be lowered onto the
block (Fig. 85).
bearings straight to prevent damage to thrust bear
ings.
(6) Install the ring dowels in the main bearing

caps (Fig. 87).
Fig. 85 Lifting Crankshaft out of Cylinder Block

(7) Remove the main bearings from the block and
the main caps. J9109-95
(8) Remove the piston cooling nozzles by using a
3/16 inch pin punch to push them out (Fig. 86). Fig. 87 install Ring Dowels
INSTALLATION (7) Install the lower main bearings in the caps.

(8) Lubricate the bearings with Lubriplate, or
CAUTION: Use only hand force to push the nozzle equivalent.
in place. If driven with a hammer, the nozzle will be (9) Numbers on the main bearings caps face the oil
damaged. cooler side of the engine with number one at the
front of the engine.
(1) Use a center punch to push the piston cooling (10) Place the caps in their respective positions.
nozzle into place. Install nozzles so they are even (11) Lubricate the main bearing bolt threads and
with or slightly below the saddle surface. underside of the bolt head with clean engine oil.
(2) Make sure the saddle surface is clean and dry. (12) Tighten the bolts evenly i n the sequence
Install the upper main bearings. shown using the following torque steps (Fig. 88).
BR 5.9L (DIESEL) ENGINE I - 195

• STEP 1—Tighten all bolts in sequence to 60 N-m
CRANKSHAFT
(44 ft. lbs.) torque. END
• STEP 2—Tighten all bolts i n sequence to 119 CLEARANCE
• STEP 3—Tighten all bolts In sequence to 176
CRANKSHAFT
GEAR
MIN. 0.100 mm (0.004 inch)
MAX. 0.430 mm (0.017 inch)
J9409-120
Fig. 90 Crankshaft End Clearance

(3) Drill two l/8th inch holes into the seal face,
180° apart.
(4) Use a slide hammer tool with a # 1 0 metal
J9109-96 screw. Pull alternating from side-to-side until the
seal is free.
Fig. 88 Main Bearing Bolt Tightening Sequence
(13) Turn the crankshaft to determine that i t will INSTALLATION
rotate freely all 360°. Check the main bearing cap (1) The sealing surface on the crankshaft must be
installations and/or the bearing sizes if the shaft does free from all oil residue to prevent seal leaks.
not turn easily. (2) I f the gear cover was replaced, use the align
(14) Push the crankshaft towards one end of its ment tool from the seal k i t to make sure the cover is
thrust and place a dial indicator as shown (Fig. 89). aligned with the crankshaft.
(3) Apply a bead of Loctite 2 7 7 to the outside
diameter of the seal.
DIAL
INDICATOR
(4) Install the pilot from the * seal k i t onto the
crankshaft.
(5) Install the seal onto the pilot and start i t into
CYLINDER
BLOCK
the gear housing cover seal bore.
(6) Remove the pilot.
(7) Use the alignment/installation tool and a plas
tic hammer to install the seal to the correct depth.
(8) Install the vibration damper, but DO NOT
tighten the damper bolt until the belt is installed.
(9) Install the drive belt.
(10) Tighten the vibration damper bolts to 125
N-m (92 ft. lbs.) torque. Use the engine barring tool
to keep the engine from rotating during torquing
J9109-97 operation.
Fig. 89 Position of Dial Indicator CRANKSHAFT REAR SEAL
(15) Zero the indicator needle and push the crank
shaft towards the other end of its thrust and record REMOVAL
the crankshaft end clearance (Fig. 90). (1) Remove the transmission (refer to Group 2 1 ,
Transmission for the proper procedure).
CRANISHAFT FRONT SEAL (2) Remove the clutch cover.
(3) Remove the clutch plate.
REMOVAL (4) Remove the flywheel.
(1) Remove the drive belt. (5) Drill holes 180° apart into the seal. Be careful
(2) Remove the vibration damper. not to get the drill against the crankshaft.
9 -196 i.9L (DIESEL) ENGINE BR
R E M O V A L A i l l l INSTALLATION (Continued)
(6) Install #10 sheet metal screws in the drilled
holes and remove the rear seal with a slide hammer
(Fig. 91).
Fig. 92 Seal Installation using Alignment Tool
Fig. 91 Crankshaft Rear Seal Removal

INSTALLATION
CAUTION: The seal lip and the sealing surface on

the crankshaft must be free from all oil residue to
prevent seal leaks.
The crankshaft and seal must be dry when the seal

is installed.
(1) install the seal pilot, provided in the replace
ment kit, on the crankshaft. Push the seal on the
pilot and crankshaft.
(2) Remove the seal pilot.
(3) Seal O.D. lubricant/sealant:
• Rubber O.D. rear crankshaft seals are lubricated Fig. 93 Crankshaft Rear Seal Housing/Gasket
with soapy water.
INSTALLATION
• Seals without rubber O.D. use Loctite 277 or
(1) Clean and dry the rear crankshaft sealing sur
equivalent sealant.
face. The seal lip and the sealing surface on the
(4) Use the alignment tool to install the seal to the
crankshaft must be free from all oil residue to pre
correct depth in the housing. Use a hammer to drive
vent seal leaks.
the seal into the housing until the alignment tool
(2) Assemble the rear seal housing and gasket to
stops against the housing (Fig. 92).
the cylinder block with the bolts.
(5) Hit the tool at the 12, 3, 6 and 9 o'clock posi
(3) Align the seal housing to the crankshaft with
tions to drive the seal evenly and prevent bending
the alignment tool provided in the seal k i t (Fig. 14).
the seal housing.
Make sure the seal housing is level with both sides of
the block oil pan rail. Tighten the bolts to 9 N-m (7
CRANKSHAFT REAR SEAL HOUSING
ft. lbs.) torque.
REMOWAL (4) Remove the alignment tool and trim the gasket
(1) Remove the rear seal housing and gasket (Fig. even with the oil pan mounting surface (Fig. 94).
93). (5) The rubber O.D. rear crankshaft seals are
(2) Support the seal area of the rear seal housing lubricated with soapy water. Seals without rubber
and press/drive out the seal using a hammer and a O.D. use Loctite 277, or equivalent.
pin pinch.
(3) Clean the rear seal housing.
5JL (DIESEL) ENGINE 9 -197
m m — — • — ^ _ — — — — — — — —
Fig. 94 Crankshaft Rear Seal Homing Alignment Fig. 96 Crankshaft Rear Seal Alignment/installation
Tool Tool
(6) Install the seal pilot (provided with the replace (7) Install the gear. The gear must be installed so
ment kit) onto the crankshaft. Push the seal onto the the bevel on the teeth is towards the crankshaft side
crankshaft (Fig. 95). of the flywheel (Fig. 97).
(7) Remove the seal pilot.
Fig. 97 Flywheel/Ring Gear Position

Fig. 95 Crankshaft Rear Seal Pilot INSTALLATION
(8) Use alignment and Installation tool packaged CAUTION: Never use the timing pin to hold the
in the seal kit (Fig. 96). Alternately, drive the seal at crankshaft en position.
the 12, 3, 6 and 9 o'clock positions to prevent bending
the seal carrier during Installation. (1) Use the engine barring tool to hold the crank
shaft when the flywheel bolts are being tightened.
FLYWHEEL RING GEAR' (2) Tighten the bolts in a criss-cross pattern to 1 3 7
N-m ( 1 0 1 ft. lbs.) torque.
REMOVAL
(1) Remove the transmission. CRANKSHAFT GEAR
(2) Remove the clutch cover.
(3) Remove the clutch plate. REMOVAL
(4) Remove the flywheel. Remove the crankshaft gear using a heavy duty
(5) Use a drift pin to drive the ring gear from the puller.
flywheel (Fig. 19). Strike the gear at several points
around the wheel until i t Is off. INSTALLATION
(6) Heat the new ring for 20 minutes i n an oven Remove all burrs and make sure the gear surface
preheated to 1 2 7 ° C (250°F). on the end of the crankshaft is smooth.
9 • 198 5.9L (DIESEL) ENGINE BR
If removed, install a new alignment pin. Drive the
pin in using a ball- peen hammer, leaving i t protrud
ing 1.60 mm (0.063 Inch) to 2.39 mm (0.094 inch)
above the crankshaft (Fig. 98).
Fig. 98 Installing Alignment Pin

Fig. 99 Oil Pump Removal
Heat the crankshaft gear for 45 minutes at a tem
perature of 121°C (250°F). ® Step 1—Tighten to 5 N-m (44 in. lbs.) torque.
o Step 2—Tighten to 24 N-m (18 ft. lbs.) torque.
CAUTION: DO NOT heat the gear longer than 45 (3) The back plate on the pump seats against the
minutes. bottom of the bore in the cylinder block. When the
pump is correctly installed, the flange on the pump
will not touch the cylinder block.
WARNING: WEAR PROTECTIVE GLOVES TO PRE (4) Measure the idler gear to pump drive gear
VENT INJURY. backlash and the idler gear to crankshaft gear back
lash (Fig. 100). The backlash should be 0.080- 0.330
Position the gear with the timing mark out and mm (0.003-0.013 inch). I f the backlash is out of lim
install i t on the crankshaft using the alignment pin. its, replace the oil pump drive gear and the idler
Make sure the gear contacts the shoulder. gear.
(5) I f the adjoining gear moves when you measure
OIL P U i P the backlash, the reading will be incorrect.
The non-intercooled turbocharged engine oil pumps
can not be used on intercooled engines.
REMOVAL
(1) Remove the radiator (refer to Group 7, Cooling
(2) Loosen the crankshaft vibration damper and
remove the drive belt.
(3) Remove the fan clutch assembly.
(4) Remove the fan hub.
(5) Remove the oil fill tube.
(6) Remove the crankshaft vibration damper.
(7) Remove the gear housing cover.
(8) Remove the four mounting bolts and pull the Fig. 100 Idler Gear to Pump Drive Gear and
pump from the bore in the cylinder block (Fig. 99). Crankshaft Gear Backlash
OIL FILTER BYPASS WALWE
INSTALLATION
(1) Lubricate the pump with clean engine oil. Fill REMOVAL
ing the pump with clean engine oil during installa (1) Remove the oil cooler cover (Fig. 101).
tion will help to prime the pump at engine start up. (2) Remove the valve from the cooler cover (Fig.
Make sure the idler gear pin is installed in the 101).
locating bore in the cylinder block.
(2) Install the pump. Tighten the oil pump mount INSTALLATION
ing bolts in two steps and in the sequence shown (1) Drive the new valve in until i t bottoms against
(Fig. 99). the step in the bypass valve bore (Fig. 102).
BR— — — — — — 5.9L (DIESEL) ENGINE 9 - 199

(2) Check the spring for height and load limita
tions (Fig. 104). Replace the spring i f out of limits.
Fig. 101 Removing Filter Bypass Valve

(2) Install the oil cooler cover.
FILTER
BYPASS
y VALVE J9509-161
Fig. 104 Oil Pressure Regulator Spring Check

INSTALLATION
(1) Clean and inspect the plunger, bore and seat
before assembly. The plunger must move freely in the
valve bore.
(2) Install the valve, spring, gasket and plug.
OIL COOLER Tighten the plug to 80 N-m (60 ft. lbs.) torque.
COVER
DISASSEMBLY A N D ASSEMBLY
J9109-15
ROCKER LEVERS
Fig. 102 Installing New Filter Bypass Valve
DISASSEMBLE
OIL P R E S S U R E REGULATOR VALVE AND SPRING
(1) Remove the retaining rings and thrust washers
(Fig. 105).
REMOVAL
(1) Remove the threaded plug, gasket, spring and (2) Remove the rocker levers (Fig. 105). DO NOT
valve (Fig. 103). disassemble the rocker lever shaft and pedestal. The
pedestal and shaft must be replaced as an assembly.
PLUG GASKET (3) Remove the locknut and adjusting screw (Fig.
105).
OIL
FILTER LOCKNUT ADJUSTING
EXHAUST SCREW
ROCKER
SPRING
LEVER
THRUST INTAKE
WASHER ROCKER
V LEVER
PEDESTAL
J9109-14 RETAINING
RING
Fig. 103 Oil Pressure Regulator J9l09-31
Fig. 105 Rocker Lever Components

9 - 210 5.9L (DIESEL) ENGINE — BR
(4) Clean all parts in a strong solution of laundry
detergent in hot water.
(5) Use compressed air to dry the parts after rins
ing in clean hot water. The pedestals are made from
powdered metal and may continue to show wetness
after they have been cleaned and dried.
(6) Inspect for excessive wear in the bore and the
contact surface for the valve stem.
(7) Measure the rocker lever bore diameter. The
maximum diameter is 19.05 mm (0.75 inch). Replace
if out of limits.
(8) Inspect the pedestal and shaft.
(9) Measure the shaft diameter. The minimum
diameter is 18.94 mm (0.746 inch). Replace i f out of
limits.
Fig. 106 Retainer Rings
ASSEMBLE
(1) Install the adjusting screw and locknut.
(2) Lubricate the shaft with clean engine oil. Be
sure to assemble the intake and exhaust rocker
levers in the correct location.
(3) Position the levers on the rocker shaft. Install
the thrust washers.
(4) Clean the push rods in the hot soapy water.
(5) Inspect the push rod ball and socket for signs
of scoring or cracks where the ball and the socket are
pressed into the tube.
(6) Check the push rods for roundness and
straightness.
(7) Install the push rods into the sockets of the
valve tappets. Lubricate the push rod sockets with
clean engine oil.
(8) Make sure the rocker lever adjusting screws Fig. 107 Proper Markings on the Piston and
are completely backed out. Connecting Rod
PISTON AND CONNECTING ROD ASSE1BLY TOP RING ' T

OP
DISASSEMBLE
(1) Remove the retainer rings from the piston (Fig.
INTERMEDIATE
106) .
R I N G
(2) Remove the piston pin. Heating the piston is
not required.
(3) Remove the piston rings (Fig. 106). OIL C O N T R O L
RING
J9109-69
ASSEMBLE
(1) Be sure the FRONT marking on the piston and Fig. 108 Piston Ring identification
the numbers on the rod and cap are oriented (Fig.
107) . Install the retaining ring into the pin groove on (5) Position each ring in the cylinder and use a
the FRONT side of the piston. piston to square i t with the bore at a depth of 89.0
(2) Lubricate the pin and bore with engine oil. mm (3.5 inch) - (Fig. 109).
(3) Install the piston pin in the opposite side of the (6) Use a feeler gauge to measure the piston ring
installed retaining pin. Pistons do not require heat gap (Fig. 1 1 0 ) .
ing to install the pin, however, the piston does need (7) The top surface of all of the rings are identified
to be at room temperature or above. with the word TOP or the supplier's MARK. Assem
(4) Determine the piston diameter and obtain the ble the rings with the word TOP or the supplier's
appropriate ring set. The piston rings can be identi MARK up.
fied as shown in (Fig. 108).
BR • 5.9L (DIESEL) ENGINE 9 - 201
OIL C O N T R O L
Fig. 109 Position of Ring in Cylinder Bore

Fig. 111 Oil Control Ring/Expander Location in
Groove
MINIMUM M A X I M U M
0 . 4 0 0 mm 0 . 7 0 0 mm
Fig. 112 Piston Ring installation Tool
TOP
( 0 . 0 1 6 0 inch) ( 0 . 0 2 7 5 inch)
INTERMEDIATE 0 . 2 5 0 mm 0 . 5 5 0 mm
( 0 . 0 1 0 0 inch) ( 0 . 0 2 1 5 inch)
OIL CONTROL 0 . 2 5 0 mm 0 . 5 5 0 mm
( 0 . 0 1 0 0 inch) ( 0 . 0 2 1 5 inch)
J9109-71
Fig. 110 Piston Ring Gap

(8) Position the oil ring expander in the oil control
ring groove (bottom groove).
(9) Install the oil control ring with the end gap
OPPOSITE the ends on the expander (Fig. 111).
(10) Install the intermediate piston ring in the sec
ond groove (Fig. 109).
(11) Install the top piston ring in the top groove Fig. 113 Piston Ring Positioning
(Fig. 112). .
(13) Install the original bearings as removed or
(12) Position the rings as shown in (Fig. 113).
install new bearings. I f new bearings are used, be
sure to obtain the proper bearing clearance (Fig.
114).
I - 202 5.9L (DIESEL) ENGINE BR
DISASSEMBLY A N D ASSEMBLY ( C o n t i n u e d )
(14) DO NOT lubricate the side of the bearing that
is against the connecting rod or cap. Apply a coat of
Lubriplate 105, or equivalent to the new upper and
lower connecting rod bearings.
STANDARD
OVERSIZE
0.250 mm (.0098 in.)

0.500 mm (.0197 in.)
0.750 mm (.0295 in.)
1.000 mm (.0394 in.)
MIN. 102.0 mm (4.0157 inch)
J9109-82
MAX. 102.1 16 mm (4 0203 inch)
Fig. 114 Connecting Rod Bearing Size Location Out-of-Round 0.038 mm (0.0015 inch)
Taper 0.76 mm (0.003 inch)
C L E A N I N G AND I N S P E C T I O N
Oversize pistons and rings are
available for bored cylinder blocks.
OIL COOLER ELEMENT AND GASKET
J9109-75
Clean the sealing surfaces. Fig. 115 Cylinder Bore Diameter
Apply 483 kPa (70 psi) air pressure to the element
to check for leaks. I f the element leaks, replace the
element.
CYLINDER HEAD
INSPECTION
Remove the cup plugs and inspect the coolant pas
sages. A large build up of rust and lime will require
removal of the cylinder block for cleaning in a hot
tank.
Inspect the cylinder bores for damage or excessive
wear. Rotate the crankshaft so the piston is at Bot Fig. 116 Cylinder Head Combustion Deck Face
tom Dead Center (BDC) to inspect the bores. Measurement
Measure the cylinder bores (Fig. 115). DO NOT REFACING HEAD SURFACE
proceed with in-chassis repair i f the bores are dam The cylinder head combustion deck may be refaced
aged or worn beyond the limits (refer to Cylinder in whatever increments necessary to clean up the
Bore Repair - Cylinder Block). surface and maintain the surface finish and flatness
Check the top surface for damage caused by the tolerances. The combined total of stock removed must
cylinder head gasket leaking between cylinders. not exceed 1.00 mm (0.03937 inch). The amount of
Inspect the block and head surface for nicks, ero stock removed each time must be steel stamped
sion, etc. above combustion deck edge, on the lower right hand
Check the head distortion (Fig. 116). The distortion corner of the rear face (Fig. 117). Check valve protru
of the combustion deck face is not to exceed 0.010 sion after head surface refacing.
mm (0.0004 inch) in any 50.8 mm (2.00 inch) diame Surface finish requirements are 1.5-3.2 microme
ter. Overall variation end to end or side to side 0.30 ters (60-126 microinch).
mm (0.012 inch).
DO NOT proceed with the in-chassis overhaul i f
the cylinder head or block surface is damaged or not
flat (within specifications).
BR 5.9L (DIESEL) ENGINE ' 9 - 203
REFERENCE
HEIGHT (MIN
.1 11 1 -1
I
7
1
J9109-144
MEASURE AT THESE POINTS
STOCK
REMOVED- Fig. 118 Measure Valve Stem Diameter
STOCK J IDENTIFICATION
TOTAL (MAX.) ' SURFACE FINISH AREA
VALWE GRINDING
The valve seat angle should be 30° (Intake Valve)
STOCK TOTAL (MAX.)
1.00 mm (0.03937 inch)
and 45° (Exhaust Valve) - (Fig. 119).
REFERENCE HEIGHT (MIN.)
INTAKE EXHAUST
94.00 ±0.25 mm
(3.7008 ±0.0010 inch)
SURFACE FINISH
1.5 to 3.2 micrometers
(60 to 128 microinches)
J9109-134
Fig. 117 Cylinder Head Stock Removal

CLEMMING
Clean the carbon from the injector nozzle seat with
a nylon or brass brush.
Scrape the gasket residue from all gasket surfaces.
Wash the cylinder head i n hot soapy water solution
^ 00 ^
(88°C or 140°F).
J9109-41
After rinsing, use compressed air to dry the cylin
der head.
Fig. 119 Valve Seat Angle
Polish the gasket surface with 400 grid paper. Use
an orbital sander or sanding block to maintain a flat Measure the rim thickness (Fig. 120). The mini
surface. mum valve rim thickness is 0.79 mm (0.031 inch).
WALWES AND WALWE SPRINGS VALVE RIM

THICKNESS
VALVES
CLEANING AID INSPECTION

Before cleaning, note the valve number. Clean the
valve heads with a soft wire wheel. Mark the valve
with the number noted above.
Polish the valve stems with crocus cloth.
Inspect for abnormal wear on the valve heads and J9109-146
stems. Replace badly worn valves.
Check for bent valves. Replace bent valves. Fig. 120 Valve Rim Thickness
Measure the valve stem diameter (Fig. 118). The Grind the face of valves to be reused.
valve stem diameter should be 7.935-7.960 mm Check the valve stem tip for flatness. I f required,
(0.3126-0.3134 inch). I f out of limits, replace the re-surface the tip.
valve. Mark the new valves with the replacement
location. VALVE GUIDES
Inspect the end of the valve stem for flatness.
I f required, resurface the valve end. INSPECTION
Inspect the valve guides for scuffing or scoring.

Measure the valve guide bore (Fig, 121). The bore Two X's stamped on the head indicate service seats
diameter should be 3.019-8.089 mm (0.3157-0.3185 have been installed (Fig. 122). Service seats can be
inch). ground.
NEW DIAMETER LIMITS

8.019-8.029 mm (0.3157-0.3165 inch)
Fig, 122 Reworked Cylinder Head Seats—Stamped
W O R N LIMIT identification
8.090 mm (0.3185 inch)
On the integral seat head, i f 0.254 mm (0.010 Inch)
J9109-135
or more has been removed from the head combustion
surface, service seats must be installed.
Fig. 121 Valve Guide Bore To determine i f the head has been previously
resurfaced, before calculating valve depth, process as
I f the valve guide bores are larger than the worn follows:
limit, the cylinder head must be machined for service (1) Check the rear lower right corner of the head
valve guides. New valve guides must be reamed to for a stamping that would indicate previous resurfac
size after they are Installed. ing (.003).
If the cylinder head needs service valve guides and (2) To verify the Information, or I f no amount Is
valve seat inserts, the valve guides should be Indicated, measure the head height (Fig. 123).
installed first. (3) I f the head height is 94.75 mm (3.730 inch) or
% greater, the valve seats may be ground, i f they have
/ALVE SPRINGS
not been ground previously.
INSPECTION
Measure the valve spring length. The approximate
free length is 60 mm (2.36 Inch) with the maximum
inclination of 1.0 mm (0.039 inch).
Measure the valve spring force. 359 N (81 lbs.) is
the minimum acceptable load required to compress
the spring to a height of 49.25 mm (1.94 inch).
If the valve spring does not meet the limits above,
replace the spring.
VALVE SEATS
INSPECTION Fig. 123 Cylinder Head Height

Cylinder head with Integral valve seats can be TAPPET
ground only once. Previously ground integral seats
must be replaced with service seats. INSPECTION
One X stamped into the head casting identify seats Inspect the tappet socket, stem and face for exces
that have been ground previously (Fig. 122). sive wear, cracks and other damage (Fig. 124).
BR — : , : — 5.9L (DIESEL) ENGINE 9 - 205
The minimum tappet stem diameter Is 15.925 mm
(0.627 Inch) - (Fig. 124). If the tappet Is out of limits,
VALVE
replace the tappet. LOBE
CAMSHAFT
JOURNAL
NORMAL
WEAR
ABNORMAL
WEAR
STEM DIAMETER-*-
J9109-152
CAMSHAFT JOURNAL DIAMETER ( M I N .
5 3 . 9 6 2 mm ( 2 . 1 2 4 5 inch)
Fig, 12& Tappet inspection
CAMSHAFT VALVE LOBE HEIGHT (MIN.)
INTAKE - 4 7 . 0 4 0 mm ( 1 . 8 5 2 inch)
INSPECTION EXHAUST - 4 6 . 7 7 0 mm ( 1 . 8 4 1 inch)
Inspect the lift pump lobe, valve lobes and bearing
LIFT PUMP LOBE DIAMETER (MIN.)
journals for wear, cracking, pitting and other dam
3 5 . 5 0 0 mm (1.398 inch)
age.
Clean the camshaft and gear with solvent and a
lint free cloth. J9109-53
Inspect the gear teeth for wear and damage. Look
for cracks at the root of the teeth. Fig. 125 Bearing Journal/Valve Lobe Measurements
Measure the bearing journals, lift pump lobe and
valve lobes (Fig. 125). OIL PUMP
BACK PLATE
OIL PUMP
CLEAN AND INSPECT

Visually inspect the lube pump gears for chips, GEROTOR
cracks or excessive wear. GEROTOR
PLANETARY
Remove the back plate (Fig. 126).
Mark T O P on the gerotor planetary using a felt tip
pen (Fig. 126).
Remove the gerotor planetary (Fig. 126).
Inspect for excessive wear or damage.
Clean all parts in solvent and dry with compressed
J9109-156
air.
Inspect the pump housing and gerotor drive for Fig. 126 Gerotor Planetary and Gerotor
damaged and excessive wear.
Install the gerotor planetary i n the original posi inch). I f the backlash is out of limits, replace the oil
tion. The chamfer must be on the O.D. and down. pump.
Measure the tip clearance (Fig. 127). Maximum
OIL PUMP
clearance is 0.1778 mm (0.007 inch). I f the oil pump
is out of limits, replace the pump.
FEELER
GAUGE
J9109-24
Fig. 130 Measure Gear Backlash
J9109-21 Install the back plate.
CYLINDER BLOCK
Fig. 127 Tip Ciearance
(1) Remove the engine assembly from the vehicle.
Measure the clearance of the gerotor drive/gerotor (2) Remove the cylinder head from the block.
planetary to port plate (Fig. 128). Maximum clear (3) Remove the camshaft.
ance is 0.127 mm (0.005 inch). I f the oil pump is out (4) Remove the piston/connecting rod assemblies.
of limits, replace the pump.
INSPECTION
PORT Measure the combustion deck face using a straight
PLATE edge and a feeler gauge (Fig. 131). The distortion of
the combustion deck face is not to exceed 0.010 mm
(0.0004 inch) i n any 50.00 mm (2.0 inch) diameter.
Overall variation end to end or side to side is 0.075
mm (0.003 inch).
I f the surface exceeds the limit, refer to Cylinder
Block Refacing.
Fig. 128 Gerotor to Port Plate Clearance

Measure the clearance of the gerotor planetary to
the body bore (Fig. 129). Maximum clearance is 0.381
mm (0.015 inch). I f the oil pump is out of limits,
replace the pump.
Fig. 131 Combustion Deck Face Measurement

Inspect the cylinder bores for damage or excessive
wear.
Measure the cylinder bores (Fig. 132). I f the cylin
der bores exceeds the limit, refer to Cylinder Bore
Repair.
Inspect the camshaft bores for scoring or excessive
wear.
Measure the camshaft bores (Fig. 133). Limit for
Fig. 129 Gerotor Planetary to Body Bore Clearance
the No.l bore applies to the ID of the bushing.
Measure the gears backlash (Fig. 130). The limits If a bore exceeds the limit, refer to Camshaft Bore
of a used pump is 0.080- 0.380 mm (0.003-0.015 Repair.
5.9L (DIESEL) ENGINE 9 - 207
C L E A N I N G AND INSPECTION ( C o n t i n u e d )
MIN. 102.0 mm (4.0157 inch)

MAX. 102.1 16 mm (4.0203 inch)
Out-of-Round 0.038 mm (0.0015 inch) BORE DIAMETER
Taper 0.076 mm (0.003 inch)
Oversize pistons and rings are MAX. 16.055 m m (0.632 inch)
available for bored cylinder blocks.
J9209-167 J9109-79
Fig. 132 Cylinder Bore Diameter Fig. 134 Tappet Bore Diameter
PISTON AND CONNECTING ROD ASSEMBLY
CLEANING
CAUTION: DO NOT use bead blast to clean the

pistons. DO NOT clean the pistons and rods in an
acid tank.
Soak the pistons i n cold parts cleaner. Soaking the

pistons overnight will usually loosen the carbon
deposits.
Wash the pistons and rods in a strong solution of
laundry detergent and hot water.
Clean the remaining deposits from the ring grooves
with the square end of a broken ring. DO NOT use a
ring groove cleaner and be sure not to scratch the
CAMSHAFT BORE DIAMETER ring sealing surface i n the piston groove.
Wash the pistons again in a detergent solution or
solvent.
MAX. 54.133 m m (2.1312 inch) Rinse the pistons. Use compressed air to dry.
J9109-78 INSPECTION
Inspect the rod journals for deep scratches, indica
Fig. 133 Camshaft Bores
tion of overheating and other damage.
Inspect the tappet bores for scoring or excessive Inspect the pistons for damage and excessive wear.
wear (Fig. 134). I f out of limits, replace the cylinder Check top of the piston, ring grooves, skirt and pin
block. bore.
I - 208 5.IL (DIESEL) ENGINE - BR
Measure the piston skirt diameter (Fig. 135). I f the PISTON
piston is out of limits, replace the piston.
1 2 mm (1 / 2 inch)
101 .823 mm
4 . 0 0 8 8 inch
J9109-63
Fig. 135 Piston Skirt Diameter J9109-65

The upper groove only needs to be inspected for
Fig. 137 Piston Pin Bore
damage.
Use a new piston ring to measure the clearance in PISTON
the intermediate ring groove (Fig. 136). I f the clear 'PIN
ance of the intermediate ring exceeds 0.152 mm
(0.006 inch), replace the piston.
Use a new oil ring to measure the clearance in the
oil groove (Fig. 136). I f the clearance exceeds 0.127
mm (0.005 inch), replace the piston.
FEELER GAUGE
J9109-66
Fig. 138 Piston Pin Diameter
CONNECTING
ROD
J9109-64
Fig. 136 Intermediate and Oil Ring Clearances

Measure the pin bore (Fig. 137). The maximum
diameter is 40.025 mm (1.5758 inch). I f the bore is
over limits, replace the piston.
Inspect the piston pin for nicks, gouges and exces
sive wear.
Measure the pin diameter (Fig. 138). The mini
mum diameter is 39.990 mm (1.5744 inch). I f the J9109-67
diameter is out of limits, replace the pin.
Inspect the rod for damage and wear. The I-Beam
Fig. 139 Connecting Rod Pin Bore
section of the connecting rod cannot have dents or
other damage. Damage to this part can cause stress CRANKSHAFT
risers which will progress to breakage.
Measure the connecting rod pin bore (Fig. 139). CLEANING AND INSPECTION
The maximum diameter is 40.042 mm (1.5764 inch). Clean the crankshaft oil galley holes with a nylon
If out of limits, replace the connecting rod. brush.
Rinse in clean solvent and dry with compressed air.
BR 5.9L (DIESEL) ENGINE I - 209

Inspect the front and rear seal contact areas of the Tighten the valve adjusting nuts to 24 N-m (18 ft.
crankshaft for scratches or grooving. lbs.) torque. Be. sure timing pin is disengaged
The service seal kit will position the seal slightly before rotating the crankshaft. Mark the pulley
deeper into the seal bore so It will contact the crank and rotate the crankshaft 3 6 0 ° .
shaft at a different location. I f this has already been
done and the crankshaft has two worn areas, Install 1 = INTAKE E = EXHAUST
a wear sleeve to provide a new contact surface for
the seal. E I E I E I
Inspect the rod and main journal for deep scores,
signs of overheating and other abnormal marks.
ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT

Use the timing pin to locate Top Dead Center
(TDC) for cylinder No.l (Fig. 140). The timing pin is
located at the back of the gear housing and below the
© © © © © ©
injection pump. Be sure to disengage the timing J9109-34 FRONT •=£>
p i n after locating top dead center. Refer to
T I M I N G P I N for more information. Fig. 141 Adjust Valve Clearance—Step 1
STEP 2
Adjust the clearance for the valves shown in (Fig.
142). The valve lash adjustment is 0.254 mm (0.010
inch) for the intake valve. The valve lash adjustment
is 0.508 mm (0.020 inch) for the exhaust valve.
Tighten the bolts to 24 N-m (18 ft. lbs.) torque.
I = INTAKE E = EXHAUST
E I I E I E
Fig, 140 Locating TDC using Timing Pin

Adjust the valves when the engine is cold, below
60°C ( 1 4 0 ° F ) . © © © © © ©
J9109-35 FRONT
STEP 1
Adjust the clearance for the valves shown in (Fig. Fig. 142 Adjust Valve Clearance—Step 2
141). The valve lash adjustment is 0.254 mm (0.010
inch) for the intake valve. The valve lash adjustment
is 0.508 mm (0.020 inch) for the exhaust valve.
SPECIFICATIONS
5.9L (DIESEL) ENGINE
Camshaft Crankshaft (Cont.)
Journal Diameter (Min.) . . . . . . . . . . . . . . . . . . . .53.962 mm Gear Backlash .0.080-0.330 mm

(2.1245 in) (0.003-0.03 in)
Valve Lobes (Min. Diameter @ Peak of Lobe)
C y l i n d e r Block
Intake 47.040 mm
Cylinder Bore
(1.852 In)
Exhaust 46770 mm Diameter. 102.116 mm
(1.841 In)
(4.0203 in)
Lift Pump Lobe (Min. Diameter @ Peak of Lobe) . . 35.500 mm
Out-of-Round (Max.) .0.038 mm
(1.398 in)
* (0.0015 in)
End Clearance . . 0.152-0.254 mm
(0.006-0.010 in)
(0.003 in)
Gear Backlash .0.080-0.330 mm
Tappet Bore Diameter 16.055 mm
(0.003-0.013 in)
(0.632 in)
Connecting l©ds Top Surface Flatness (Max. Overall Variation) 0.075 mm
Pin Bore Diameter (Max.) . . , 40.042 mm (0.003 in)
(1.5764 in) Max. Variation any 50 mm (2 in) Diameter Area . . . 0.010 mm
Side Clearance . .0.100-0.300 mm (0.0004 in)
(0.004-0.012 in) Refacing Combustion Deck
First Reface 0.250 mm
Crankshaft
(0.0098 in)
Main Bearing Journal Diameter Second Reface . . . . . . . . . . . . . . . . . . . . . . . . . . 0.250 mm
(0.0098 in)
Standard 82.962 mm Total Reface 0.500 mm
(3.2662 in) (0.0197 in)
Machined 0,25 mm . . 82.712 mm Surface Finish . 1.50-3.20 micrometers
(0.0098 in) (3.2564 in) (60-126 microinches)
Machined 0.50 mm . 82.462 mm Main Bearing Bore Diameter (Max.) . . . . . . . . . . . 83.106 mm
(0.0197 in) (3.2465 in) with Bearing Installed (3.2719 in)
Machined 0.75 mm 82.212 mm Camshaft Bore Diameter (Max.)
(0.0295 in) (3.2367 in)
Machined 1.00 mm . . . . 81.962 mm No. 1 without Bushing 57.258 mm
0.0394 in) (3.2269 in) (2.2543 in)
O u t - o f - R o u n d (Max.) .0.050 mm Nos. 1-7 with Bushing 54.133 mm
(0.002 in) (2.1312 in)
C y l i n d e r Head
(0.0005 in)
Oil Clearance (Max.) .0.119 mm Flatness Max. Overall . . . .0.030 mm
(0.0047 in) (0.012 in)
Connecting Rod Journal Diameter Max. Variation within 0.01 mm (0.0004 in) in any
Standard .68.962 mm 50.8 mm (2.00 in) diameter area.
(2.7150 in)
Machined 0.25 mm . . . . . . . . . . . . . . . 68.712 mm Valve Seat Angle
(0.0098 in) (2.7052 in)
Machined 0.50 mm 68.462 mm Intake ....30°
(0.0197 in) (2.6954 in)
Exhaust . . . -45°
Machined 0.75 mm . . . . . . . . . . . . . . . . . . . . . . 68.212 mm
(0.0295 in) (2.6855 in)
Machined 1.00 mm 67.962 mm Valve Seat Width
(0.0394 in) (2.6757 in)
Minimum 1.52 mm
(0.002 in) (0.060 in)
Taper (Max) 0.013 mm Maximum 2.03 mm
(0.0005 in) (0.080 in)
Oil Clearance 0.089 mm lappets
(0.0035 in)
End Clearance . 0.100-0.430 mm Stem Diameter. 15.925 mm
(0.004-0.017 in) (0.627 in)
ENGINE SPECIFICATIONS J9409-4
5.9L (DIESEL) ENGINt
Tip Clearance (Max.) . 0.1778 mm Diameter (Min.) 39.990 mm

(0.007 in) (1.5744 in)
Gerotor Drive/Planetary to Port 0.127 mm Bore Diameter (Max.) 40.025 mm
Plate Clearance (Max) (0.005 in) (1.5758 in)
Gerotor Planetary to Body . 0.381 mm Piston Rings
Clearance (Max.) (0.015 in)
Gear Backlash (Used Pump) .... 0.080-0.380 mm Ring End Gap
(0.003-0.015 in)
Top Ring 0.400-0.700 mm
Oil Pressure (minimum) (0.016-0.0275 in)
Intermediate Ring . . . . . . . . . . . . . . . . . .0.250-0.550 mm
At Idle Speed* . . .69kPa (0.010-0.0215 in)
(10 psi) Oil Control Ring .0.250-0.550 mm
At 2,500 rpm 207 kPa (0.010-0.0215 in)
(30 psi)
Valves
Regulating Valve Opening Pressure 448 kPa
(65 psi) Clearance — Intake .0.25 mm
(0.010 in)
' CAUTION: If pressure is ZERO at curb idle, Exhaust. . . . . . . . . . . . . . . .0.51 mm
DO NOT run engine a t 2,500 rpm. (0.020 in)
Guide Diameter . . . 8.019-8.089 mm
(0.3157-0.3185 in)
Stem Diameter 7.935-7.960 mm
Oil Filter (0.3126-0.3134 in)
Depth (Installed) . . .0.99-1.52 mm
Differential Pressure to Open Filter Bypass 172.3 kPa (0.039-0.060 in)
(25 psi)
Valve Springs
Pistons
Free Standing Length • 60 mm
Skirt Diameter . . . . ....... 101.880-101.823 mm (2.36 in)
(4.0110-4.0088 in) Inclination (Max.) . . . . . . . . . . . . L O O mm
1
Ring Groove Depth (0.039 in)
Minimum Load @49.25 mm-359 N
Intermediate 0.150 mm (@1.94 in-81 lbs)
(0.006 in)
Oil Control 0.130 mm
(0.005 in) J9509-159
Air Fuel Control Fitting (In Head) 8 N»m (6 ft. lbs.) Intercooler Attaching Bolts.... 2N®m 17 in. lbs.)
Intercooler Duct Clamp Nuts . 8 N®m 72 in. lbs.)
Battery Cable (Negative)
Mounting to Block .. 77 N*m 57 ft. lbs.) Lifting Bracket (Rear) 77 N®m 57 ft. lbs.)
Belt Tensioner Mounting 43 N*m 32 ft. lbs.)
I Cooler Assembly 24 N®m 18 ft. lbs.)
Block Heater Mounting 12 N«m 9 ft. lbs.)
I Fill Tube Bracket Bolt 43 N®m 32 ft. lbs.)
Cab Heater Hose Clamp 4 N®m 35 in. lbs.)
I Filter.... 3/4 Turn A f tter Contact
Cab Heater Tubing Clamp Mounting 9 N*m 7 ft. lbs.)
I Pan Drain Plug 80 N®m 60 ft. lbs.)
Camshaft Thrust Plate Bolts 24 N»m i 18 ft. lbs.)
I Pan Bolts... 24N®m 18ft.lbs.)
Clutch Cover Mounting to 80 N®m 60 ft. lbs.)
I Pressure Regulator Plug
Fiywheel Bolts 23 N»m 17 ft. lbs.)
I Pressure Sender/Switch 16N®m 12ft.lbs.)
Connecting Rod Bolts
Step 1 (Alternately Tighten) 35 N®m 26 ft. lbs.) I Pump Mounting Bolts 24N®m 18 ft. lbs.)
Step 2 (Alternately Tighten) 70 N«m 51 ft. lbs.) I Suction Tube (Flange) 24 NTn 18ft.lbs.)
Step 3 (Alternately Tighten)... 100 N®m 73 ft. lbs.)
I Suction Tube Brace Bolt 24 N*m 18ft. lbs.)
Cooling Fan Mounting to Fan Clutch 20 N®m 15 ft lbs.)
I Supply Fitting for Vacuum Pump . 10N®m 7V2 ft. lbs.)
Crankshaft Main Bearing Bolts
Step 1 60 N®m 45 ft. lbs.) Rear Mount — Support
Step 2 119N®m 88 ft. lbs.) Cushion-to-Crossmember Nut 47N®m 35 ft. lbs.)
Step 3 1 76 N®m 129 ft. lbs.)
Rear Mount — Support Cushion-to-Trans.
Cylinder Head Bolts Support Bracket Nuts 47N®m 35 ft. lbs.)
All Bolts 90N«m 66 ft. lbs.)
All Long Bolts... 120N®m 89 ft. lbs.) • Rear Mount — Transmission Support
Tighten All Bolts an Additional........... 90° Bracket Bolts.... 102N®m 75 ft. lbs.)
Rear Support Plate-to-Transfer
Exhaust Manifold Bolts 43 N*m 32 ft. lbs.) Case Bolts 41 N®m 30ft.lbs.)
Fan Clutch Mounting/Fan Hub Rocker Arm Bolts 18ft. lbs.)

24N®m
(Left Hand Threads) 57 N»m 42 ft. lbs.) Starter Mounting Bolts 50 ft. lbs.)
68 N®m
Fan Hub Bracket Mounting 24 N®m 18 ft. lbs.)
Torque Converter Drive Plate Bolts.... 270 in. lbs.)
Fan Hub Bearing Retaining Capscrew .... 77 N m 57ft.lbs.)
#
31 N®m
Transfer Case-to-lnsulator Mounting
Fan Pulley to Fan Hub 9 N®m 7 ft. lbs.)
Plate Nuts
Fan Shroud Mounting Nuts 11 N®m95 in. lbs.) 204 N®m 150ft.lbs.)
Transmission Support Bracket Bolts
Flywheel Bolts 137N®m 101 ft. lbs.) (2WD)
68 N®m 50 ft. lbs.)
Flywheel Housing Adaptor. 77 N• m 57ft.lbs.) Transmission Support Spacer Bolts
Front Mount — Thru-Bolt Nut 68 N*m 50 ft. lbs.) (4WD) 50 ft. lbs.)
68 N®m
Front Mount — Engine Support Transmission Support Spacer-to-lnsulator
Mounting Plate Nuts (4WD)
Bracket/Cushion Bolts 176 N®m 140ft.lbs.) 204 N®m
150ft.lbs.)
]
Generator Mounting Bolts 41 N®m 30 ft. lbs.) Vacuum Pump Oil Supply Line 10N®m 7 /2 ft. lbs.)
Generator Pulley. .. 80 N®rrt 59 ft. lbs.) Vibration Damper Retainer Bolts 125N®m 92 ft. lbs.)
Generator Support (Upper) 24 N • m 18ft. lbs.)
Water Pump 24 N*m 8 ft. lbs.)
Gear Cover 24 N®m 18ft. lbs.)
Gear Housing Bolts 24 N«m 1 8 f t . lbs.)
Intake Manifold Cover Bolts 24 N*m 18ft. lbs.) J9509-160

EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 1
EXHAUST S Y S T E M AND H N T A K E MANIFOLD

CONTENTS
page page
GENERAL INFORMATION EXHAUST PIPE—DIESEL 12

CATALYTIC CONVERTER 1 EXHAUST TAILPIPE 6
EXHAUST HEAT SHIELDS 2 EXHAUST TAILPIPE—DIESEL 13
EXHAUST SYSTEM 1. HEAT SHIELDS—DIESEL 13
DESCRIPTION AND OPERATION INTAKE MANIFOLD COVER—AIR INTAKE
ENGINE EXHAUST MANIFOLD—V-6 and V-8 HEATER 15
ENGINES 3 INTAKE MANIFOLD V-10 9
EXHAUST MANIFOLD—V-10 ENGINE 3 INTAKE MANIFOLD—V-6 and V-8 ENGINES . . . 7
INTAKE MANIFOLD—V-10 ENGINE 3 INTERCOOLER—DIESEL 17
INTAKE MANIFOLD—V-6 and V-8 ENGINES . . . 3 MUFFLERS 5
INTERCOOLER—CHARGE AIR COOLER 3 MUFFLER—DIESEL 13
TURBOCHARGER—5.9L DIESEL ENGINE 3 TURBOCHARGER DIESEL 16
DIAGNOSIS AND TESTING CLEANING AND INSPECTION
EXHAUST SYSTEM DIAGNOSIS 4 CATALYTIC CONVERTOR 19
INTAKE MANIFOLD DIAGNOSIS 4 EXHAUST MANIFOLD 18
REMOVAL AND INSTALLATION EXHAUST PIPE 18
CATALYTIC CONVERTERS 5 INTAKE MANIFOLD 18
CATALYTIC CONVERTERS—DIESEL 12 INTERCOOLER—CHARGE AIR COOLER 19
ENGINE EXHAUST MANIFOLD—V-6 and V-8 ADJUSTMENTS
ENGINES 11 WASTEGATE ADJUSTMENT 19
EXHAUST HEAT SHIELDS 6 SPECIFICATIONS
EXHAUST MANIFOLD V-10 11 TORQUE SPECIFICATIONS 21
EXHAUST MANIFOLD—DIESEL 13 TURBOCHARGER SPECIFICATIONS 21
EXHAUST PIPE 4
GENERAL INFORMATION bolt threads, corrosion damage and worn, cracked or

broken hangers. Replace all components that are
EXHAUST SYSTEM badly corroded or damaged. DO NOT attempt to
The gasoline engine exhaust system consists of repair.
engine exhaust manifolds, exhaust pipes, catalytic When replacement is required, use original equip
converter(s), extension pipe (if needed), exhaust heat ment parts (or their equivalent). This will assure
shields, muffler and exhaust tailpipe (Fig. 1). proper alignment and provide acceptable exhaust
The diesel engine exhaust system consists of an noise levels.
engine exhaust manifold, turbocharger, exhaust pipe,
catalytic converter, extension pipe (if needed), muffler CAUTION: Avoid application of rust prevention
and exhaust tailpipe (Fig. 2). compounds or undercoating materials to exhaust
The engine exhaust manifolds on gasoline engines system floor pan exhaust heat shields. Light over-
are equipped with ball flange outlets to assure a spray near the edges is permitted. Application of
tight seal and strain free connections. coating will result in excessive floor pan tempera
The exhaust system must be properly aligned to tures and objectionable fumes.
prevent stress, leakage and body contact. I f the sys
tem contacts any body panel, it may amplify objec
CATALYTIC CONVERTER
tionable noises from the engine or body.
There is no regularly scheduled maintenance on
When inspecting an exhaust system, critically
any Mopar® stainless steel catalytic converter body.
inspect for cracked or loose joints, stripped screw or
11 - 2 EXHAUST SYSTEM AND INTAKE MANIFOLD BR
5.9L (HEAVY DUTY)

8.0L
J9511-4
Fig. 1 Exhaust System—i soiine Engines (Typical)

Excessive heat can result in bulging or other distor releases additional heat in the exhaust system.
tion, but excessive heat will not be the fault of the Under severe operating conditions, the temperature
converter. If unburned fuel enters the converter, over increases i n the area of the reactor. Such conditions
heating may occur. I f a converter is heat-damaged, can exist when the engine misfires or otherwise does
correct the cause of the damage at the same time the not operate at peak efficiency. DO NOT remove spark
converter is replaced. Also, inspect all other compo plug wires from plugs or by any other means short
nents of the exhaust system for heat damage. out cylinders. Failure of the catalytic converter can
Unleaded gasoline must be used in gas engines to occur due to a temperature increase caused by
avoid contaminating the catalyst core. unburned fuel passing through the converter.
DO NOT allow the engine to operate at fast idle for
EXHAUST HEAT SHIELDS extended periods (over 5 minutes). This condition
Exhaust heat shields are needed to protect both may result in excessive temperatures in the exhaust
the vehicle and the environment from the high tem system and on the floor pan.
peratures developed by the catalytic converter. The
combustion reaction facilitated by the catalyst
BR EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 3
Fig. 2 Exhaust System- -Diesel Engines (Typical)

D E S C R I P T I O N AND O P E R A T I O N INTAKE MANIFOLD—V-6 and V-8 ENGINES
The aluminum intake manifold is a single plane
TURBOCHARGER—5.9L DIESEL ENGINE design with equal length runners. The manifold is
A turbocharger is used to force more air into the , sealed by flange side gaskets' with front and rear
engine cylinders. Exhaust gas energy is used to turn cross-over gaskets.
the turbine wheel and shaft. At the other end of the
shaft is the compressor wheel. The compressor wheel INTAKE MANIFOLD—V-10 ENGINE
draws air i n and forces i t into the engine cylinders The aluminum intake manifold has two plenum
through the intake manifold. chambers an upper and lower which supply air to
five runners each. Passages across the longitudinal
NOTE; Supplying increased air flow to the engine center of the manifold feed air from the throttle body
provides: to the plenum chambers.
• Improved engine performance ENGINE EXHAUST MANIFOLD—V-6 and V-8
• Lower exhaust smoke density
ENGINES
• Improved operating economy
Engine exhaust manifolds are LOG type with port
• Altitude compensation
ing for air injection into the LOG.
9 Noise reduction.
EXHAUST MANIFOLD—V-10 ENGINE
INTERCOOLER—CHARGE AIR COOLER
Engine exhaust manifolds are made of high molyb
Intake air is drawn through the air cleaner and
denum ductile cast iron. A special ribbed design helps
into the turbocharger compressor housing. Pressur
control permanent dimensional changes during heat
ized air from the turbocharger then flows forward
cycles.
through the charge air cooler (intercooler) located i n
front of the radiator. From the charge air cooler
(Intercooler) the air flows back into the intake man
ifold.
The charge air cooler (Intercooler) is a heat
exchanger that uses air flow to dissipate heat from
the intake air. As the turbocharger increases air
pressure, the air temperature increases. Lowering
the intake air temperature increases engine effi
ciency and power.
BR
11 - 4 EXHAUST SYSTEM AND INTAKE MANIFOLD
D I A G N O S I S AND T E S T I N G
EXHAUST SYSTEM DIAGNOSIS
CONDITION POSSIBLE C A U S E COiiECflON
EXCESSIVE EXHAUST NOISE 1. Leaks at pipe joints. 1. Tighten clamps at leaking joints.
2. Burned or blown-out muffler. 2. Replace muffler assembly. Check
exhaust system.
3 . Burned or rusted-out exhaust pipe. 3. Replace exhaust pipe.
4 . Exhaust pipe leaking at manifold flange. 4 . Tighten connection attaching nuts.
5 . Exhaust manifold cracked or broken. 5 . Replace exhaust manifold.
6 . Leak between exhaust manifold and 6 . Tighten exhaust manifold to cylinder
cylinder head. head stud nuts or bolts.
7 . Restriction in muffler or tail pipe. 7. Remove restriction, if possible. Replace
muffler or tail pipe, as necessary.
LEAKING EXHAUST GASES 1. Leaks at pipe joints. 1. Tighten clamps at leaking joints.
2. Damaged or improperly installed gaskets. 2. Replace gaskets, as necessary.
ENGINE HARD TO WARM UP 1. Blocked crossover passage in intake 1. Remove restriction or replace intake
OR WILL NOT RETURN TO manifold. manifold.
NORMAL IDLE
J9211-3
INTAKE MANIFOLD DIAGNOSIS (5) Disconnect the exhaust pipe from the support
An intake manifold leak is characterized by lower hangers on the 5.9L (Heavy Duty) and the 8.0L
than normal manifold vacuum. Also, one or more cyl engines (Fig. 4).
inder may not be fuctioning. (6) Remove the exhaust pipe.
WARNING: U S E EXTREME CAUTION WHEN THE

ENGINE IS OPERATING. DO NOT PUT YOUR
HANDS NEAR THE P U L L E Y S , B E L T S OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine allowing i t to warm up.

(2) Inspect for disconected vacuum hoses or hard
ened or cracked vacuum lines.
(3) With a spray bottle, spray a small stream of
water on the suspect area.
(4) I f there is a change i n RPM'S, the suspected
leak has been found.
(5) Repair as required.
R » M A U B INSTALLATION
Fig. 3 Exhaust Pipe for 3.9L, 5.2L and 5.9L—Light
EXHAUST PIPE Duty
INSTALLATION
REMOVAL
(1) Connect the exhaust pipe support hangers on
(1) Raise and support the vehicle. the 5.9L (Heavy Duty) and the 8.0L engine (Fig. 4).
(2) Saturate the bolts and nuts with heat valve (2) Position the exhaust pipe for proper clearance
lubricant. Allow 5 minutes for penetration. with underbody parts.
(3) Remove exhaust manifold bolts, retainers and
nuts (Fig. 3) (Fig. 4).
(4) Remove the clamp nuts (Fig. 3) (Fig. 5).
EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 5
mm
f?ER/l@WAL A N D I N S T A L L A T I O N (Continued)
(2) Saturate the bolts and nuts with heat valve
lubricant. Allow 5 minutes for penetration.
(3) Remove clamps and nuts (Fig. 3) (Fig. 5) (Fig.
6).
Fig. 4 Exhaust Pipe for 5.9L—Heavy Duty and 8.0L
Fig. 6 Catalytic Converter Clamp Location for

5.9L—Heavy Duty and 8.0L
(4) Disconnect the catalytic converter from the
support hanger on the 3.9L, 5.2L and 5.9L—Light
Duty engines (Fig. 3).
(5) Remove the catalytic converter.
INSTALLATION
(1) Connect the support hanger on the 3.9L, 5.2L
and 5.9L—Light Duty engines (Fig. 3).
(2) Assemble converter and clamps loosely to per
mit proper clearance with exhaust heat shields and
underbody parts.
(3) Tighten all clamp nuts to 43 N-m (32 ft. lbs.)
torque.
(5) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, i f needed.
Fig. 5 Exhaust Pipe Clamp Location for 5.9L—Heavy
MUFFLERS
Duty and 8.0L
(3) Position the exhaust pipe to manifold. Install REMOVAL
the bolts, retainers and nuts. Tighten the nuts to 34 (1) Raise and support the vehicle.
N-m (25 ft. lbs.) torque. (2) Saturate the clamp nuts with heat valve lubri
(4) Tighten the clamp nuts to 43 N-m (32 ft. lbs.) cant. Allow 5 minutes for penetration.
torque. (3) Disconnect the muffler hanger (Fig. 6) (Fig. 7).
(5) Lower the vehicle. (4) Remove clamps and nuts (Fig. 6) (Fig. 7).
(6) Start the engine and inspect for exhaust leaks (5) Remove the muffler.
Adjust the alignment, i f needed. INSTALLATION
(1) Assemble muffler and clamps loosely to permit
CATALYTIC CONVERTERS proper alignment of all parts.
(2) Connect the muffler hanger.
REMOVAL (3) Tighten the clamp nuts to 43 N-m (32 ft. lbs.)
(1) Raise and support vehicle. torque.
mm
11 - § EXHAUST SYSTEM AND INTAKE MANIFOLD
Fig. 7 Muffler for 3.9L, 5.2L and 5.9L-Light Duty

Engines
Fig. 9 Extension Pipe
EXHAUST TAILPIPE INSTALLATION
(1) Loosely assemble exhaust tailpipe and exten
REMOVAL sion pipe, i f used, to permit proper alignment of all
(1) Raise and support the vehicle. parts.
(2) Saturate the clamp nuts with heat valve lubri (2) Connect the support hangers (Fig. 8) (Fig. 9).
cant. Allow 5 minutes for penetration. (3) Position the exhaust tailpipe and extension
(3) Disconnect the exhaust tailpipe support hanger pipe, i f used, for proper clearance with the underbody
(Fig. 8). I f used, disconnect the extension pipe sup parts.
port hanger (Fig. 9). (4) Tighten all clamp nuts to 43 N-m (32 ft. lbs.)
(4) Remove clamps and nuts (Fig. 8). torque.
(5) Remove the exhaust tailpipe and extension (5) Lower the vehicle.
pipe, i f used. (6) Start the engine and inspect for exhaust leaks
HANGER
EXHAUST HEAT SHIELDS
REMOVAL
(2) Remove the nuts or bolts holding the exhaust
heat shield to the floor pan, crossmember or bracket.
(3) Slide the shield out around the exhaust system.
INSTALLATION
(1) Position the exhaust heat shield to the floor
pan, crossmember or bracket and install the nuts or
bolts.
(2) Tighten the nuts and bolts.
Fig. 8 Exhaust Tailpipe
BR EXHAUST SYSTEM AND INTAKE MANIFOLD 11-7

INTAKE MANIFOLD—V-6 and V-8 ENGINES (a) Turn the intake manifold upside down. Sup
port the manifold.
REMOVAL (b) Place a new plenum pan gasket onto the seal
(1) Disconnect the negative cable from the battery. rail of the intake manifold. Position the pan over
(2) Drain the cooling system (refer to Group 7, the gasket. Align all the gasket and pan holes with
Cooling System for the proper procedures). the intake manifold.
(3) Remove the generator. (c) Hand start all bolts.
(4) Remove the air cleaner. (d) Tighten the bolts, in sequence (Fig. 11), as
(5) Perform the Fuel System Pressure release pro follows:
cedure (refer to Group 14, Fuel System). Disconnect • Step 1—Tighten bolts to 2.7 N-m (24 in. lbs.)
the fuel lines. torque.
(6) Disconnect the accelerator linkage and i f so • Step 2—Tighten bolts to 5.4 N-m (48 in. lbs.)
equipped, the speed control and transmission kick- torque.
down cables. • Step 3—Tighten bolts to 9.5 N-m (84 in. lbs.)
(7) Remove the return spring. torque.
(8) Remove the distributor cap and wires. • Step 4—Check that all bolts are tighten to 9.5
(9) Disconnect the coil wires. N-m (84 in. lbs.) torque.
(10) Disconnect the heat indicator sending unit
V-6 V-8
wire.
(11) Disconnect the heater hoses and bypass hose.
(12) Remove the closed crankcase ventilation and
evaporation control systems.
(13) Remove intake manifold bolts.
(14) Lift the intake manifold and throttle body out
of the engine compartment as an assembly.
(15) Remove and discard the flange side gaskets
and the front and rear cross-over gaskets.
(16) Remove the throttle body bolts and lift the
throttle body off the intake manifold (Fig. 10). Dis
card the gasket.
FUEL RAIL FUEL RAIL
MOUNTING BOLTS CONNECTING
HOSES
J9311-14
Fig. 11 Plenum Pan Bolt Tightening Sequence

(2) Using a new gasket, install the throttle body
onto the intake manifold. Tighten the bolts to 23 N-m
J9409-134
(3) Place the 4 plastic locator dowels into the holes
in the block (Fig. 12).
Fig. 10 Throttle Body Assembly (4) Apply Mopar® Silicone Rubber Adhesive Seal
ant, or equivalent, to the four corner joints. An exces
(17) Remove the plenum pan as follows: sive amount of sealant is not required to ensure a
(a) Turn the intake manifold upside down. Sup leak proof seal. However, an excessive amount of
port the manifold. sealant may reduce the effectiveness of the flange
(b) Remove the bolts and lift the pan off the gasket. The sealant should be slightly higher than
manifold. Discard the gasket. the cross-over gaskets, approximately 5 mm (0.2 in).
(5) Install the front and rear cross-over gaskets
INSTALLATION
onto the dowels (Fig. 12).
(1) Install the plenum pan, i f removed, as follows:
(6) Install the flange gaskets. Ensure that the ver
tical port alignment tab is resting on the deck face of
FRONT CROSS-OVER GASKET (7) Carefully lower intake manifold into position
on the cylinder block and cylinder heads. Use the
alignment dowels in the cross-over gaskets to posi
tion the intake manifold. After intake manifold is in
place, inspect to make sure seals are i n place.
(8) Install the intake manifold bolts and tighten as
follows:
(a) V-6 ENGINE— (Fig. 14)
• Step 1—Tighten bolts 1 and 2 to 8 N-m (72 in.
lbs.) torque. Tighten i n alternating steps 1.4 N-m (12
in. lbs.) torque at a time.
© Step 2—Tighten bolts 3 through 12, in sequence,
• Step 3—Check that all bolts are tighten to 8
• Step 4—Tighten all bolts, in sequence, to 16 N-m
REAR CROSS-OVER GASKET J9209-99 (b) V-8 ENGINE— (Fig. 15)
INTAKE
Fig. 12 Cross-Over Gaskets and Locator Doweis MANIFOLD
the block. Also the horizontal alignment tabs must be
in position with the mating cylinder head gasket tabs
(Fig. 13). The words MANIFOLD SIDE should be vis
ible on the center of each flange gasket.
FLANGE GASKET
\
N\NII--OLL> S I DL
O n O O n O r
FRONT OF ENGINE
J9209-59
Fig. 14 Intake Manifold Bolt Tightening Sequence—

V-6
• Step 1—Tighten bolts 1 through 4, in sequence,
to 8 N-m (72 in. lbs.) torque. Tighten in alternating
steps 1.4 N-m (12 in. lbs.) torque at a time.
• Step 2—Tighten bolts 5 through 12, in sequence,
• Step 4—Tighten all bolts, in sequence, to 16 N-m
CYLINDER
HEAD GASKET J9209-101 • Step 5—Check that all bolts are tighten to 16
Fig. 13 intake Manifold Flange Gasket Alignment
BR — — — — — — - EXHAUST SYSTEM AND INTAKE MANIFOLD 11-9
J9209-60
Fig, 15 intake Manifold Bolt Tightening Sequence—

Fig. 16 Generator and A/C Compressor Braces
¥-8
(9) Install closed crankcase ventilation and evapo
ration control systems.
(10) Connect the coil wires.
(11) Connect the heat indicator sending unit wire.
(12) Connect the heater hoses and bypass hose.
(13) Install distributor cap and wires.
(14) Hook up the return spring.
(15) Connect the accelerator linkage and i f so
down cables.
(16) Install the fuel lines.
(17) Install the generator and drive belt. Tighten
torque. Tighten the adjusting strap bolt to 23 N-m
tem for the proper adjusting of belt tension.
Fig. 17 Air Intake Housing
(18) Install the air cleaner.
(19) Fill cooling system (refer to Group 7, Cooling (8) Disconnect the accelerator linkage and i f so
System for the proper procedure). equipped, the speed control and transmission kick-
(20) Connect the negative cable to the battery. down cables.
(9) Remove the coil assemblies with the ignition
INTAKE MANIFOLD V-10 cables.
(10) Disconnect the vacuum lines.
\EMOWAL (11) Disconnect the heater hoses and bypass hose.
(1) Disconnect the negative cable from the battery. (12) Remove the closed crankcase ventilation and
(2) Drain the cooling system (refer to Group 7, evaporation control systems.
Cooling System for the proper procedures). (13) Remove the throttle body bolts and lift the
(3) Remove the accessory drive belt (refer to Group throttle body off the upper intake manifold (Fig. 18).
7, Cooling System for the proper procedures). Discard the gasket.
(4) Remove the generator brace and generator (14) Remove upper intake manifold bolts.
(Fig. 16). (15) Lift the upper intake manifold out of the
(5) Remove the A/C compressor brace (Fig. 16). engine compartment (Fig. 18). Discard the gasket.
Remove the compressor and set aside. (16) Remove the lower intake manifold bolts and
(6) Remove the air cleaner cover and filter. remove the manifold (Fig. 19).
Remove the air cleaner housing (Fig. 17). Discard the (17) Discard the lower intake manifold gaskets
gasket. (Fig. 20).
(7) Perform the Fuel System Pressure release pro
cedure (refer to Group 14, Fuel System). Disconnect
the fuel lines.
11 - 1 0 EXHAUST SYSTEM AND INTAKE MANIFOLD
REHOWAL AND INSTALLATION (Continued)
UPPER INTAKE THROTTLE LOWER
INTAKE MANIFOLD SEALANT
MANIFOLD BODY (MPI) INTAKE
GASKET
MANIFOLD
Fig. 18 Upper Intake Manifold and Throttle Body
J9409-65
Fig. 20 Lower Intake Manifold Gaskets

.LOCATOR DOWELS-
INTAKE MANIFOLD GASKETS
J951M
LOCATOR DOWELS J9409-64
Fig. 19 Lower Intake Manifold
INSTALLATION Fig. 21 Intake Manifold Flange Gasket Alignment
(1) Install the intake manifold side gaskets. Be (6) Using a new gasket, position the upper intake
sure that the locator dowels are positioned in the manifold onto the lower intake manifold.
head (Fig. 21). (7) Finger start all bolts, alternate one side to the
(2) Peel off the protective paper (blue - rear and other.
brown - front) and press firmly onto the block (Fig. (8) Tighten upper intake manifold bolts in
20). BE SUEE THE BLOCK IS O I L FREE.. Align sequence to 22 N-m (16 ft. lbs.) torque (Fig. 18).
ing slots in end seals with notches in intake manifold (9) Using a new gasket, install the throttle body
gaskets. onto the upper intake manifold. Tighten the bolts to
(3) Insert Mopar® Silicone Rubber Adhesive Seal 23 N-m (200 in. lbs.) torque.
ant, or equivalent, into the four corner pockets (Fig. (10) Install closed crankcase ventilation and evap
20). F i l l the pocket, b u t DO NOT overfill. oration control systems.
(4) The lower intake manifold MUST be installed (11) Connect the heater hoses and bypass hose.
within 3 minutes of sealant application. Carefully (12) Connect the vacuum lines.
lower intake manifold into position on the cylinder (13) Install the coil assemblies and the ignition
block and heads. After intake manifold is in place, cables.
inspect to make sure seals and gaskets are in place. (14) Connect the accelerator linkage and i f so
Finger start all the lower intake bolts. equipped, the speed control and transmission kick-
(5) Tighten the lower intake manifold bolts in down cables.
sequence to 54 N-m (40 ft. lbs.) torque (Fig. 19). (15) Install the fuel lines.
BR EXHAUST SYSTEM AND INTAKE MANIFOLD 11-11

(16) Using a new gasket, install the air cleaner
housing. Tighten the nuts to 11 N-m (96 in. lbs.)
torque. Install the air cleaner filter and cover.
(17) Install the A / C compressor. Position the com
pressor brace and install the bolts. Tighten the brace
(18) Install the generator. Position the generator
brace and install the bolts. Tighten the brace bolts to
(19) Install the accessory drive belt (refer to Group
7, Cooling System).
ENGINE EXHAUST MANIFOLD—f-l and ¥ - 8

ENGINES Fig. 22 Engine Exhaust Manifold Installation—3.9L
Engine
REMOVAL
(3) Remove the bolts and nuts attaching the
exhaust pipe to the engine exhaust manifold.
(5) Remove the exhaust heat shields.
(6) Remove bolts, nuts and washers attaching
manifold to cylinder head.
(7) Remove manifold from the cylinder head.
INSTALLATION
CAUTION: If the studs came out with the nuts

when removing the engine exhaust manifold, Install
new studs. Apply sealer on the coarse thread ends. J931M1
Water leaks may develop at the studs if this precau
tion is not taken. Fig. 23 Engine Exhaust Manifold Installation—5.2U
5.9L Engines
(1) Position the engine exhaust manifolds on the EXHAUST MANIFOLD V-10
two studs located on the cylinder head. Install coni
cal washers and nuts on these studs (Fig. 22) (Fig. REMOVAL
23). (1) Disconnect the negative cable from the battery.
(2) Install two bolts and conical washers at the (2) Raise and support the vehicle.
inner ends of the engine exhaust manifold outboard (3) Remove the bolts and nuts attaching the
arms. Install two bolts WITHOUT washers on the exhaust pipe to the engine exhaust manifold.
center arm of engine exhaust manifold (Fig. 22) (Fig. (4) Lower the vehicle.
23). Starting at the center arm and working outward, (5) Remove the exhaust heat shields (Fig. 24).
tighten the bolts and nuts to 34 N-m (25 ft. lbs.) (6) Right exhaust manifold and discard the gasket.
torque. (7) Right exhaust manifold—Remove the dipstick
(3) Install the exhaust heat shields. bracket from the manifold.
(4) Raise and support the vehicle. (8) Remove bolts attaching manifold to cylinder
(5) Assemble exhaust pipe to manifold and secure head.
with bolts, nuts and retainers. Tighten the bolts and (9) Remove manifold from the cylinder head. Dis
nuts to 34 N-m (25 ft. lbs.) torque. card the gasket.
(7) Connect the negative cable to the battery. INSTALLATION
(1) Using a new gasket position the engine
exhaust manifold onto the cylinder head. Install bolts
BR
11 - 12 EXHAUST SYSTEM AND INTAKE MANIFOLD
EXHAUST
MANIFOLD
HEATED
OXYGEN SENSOR
WIRE SPRINGS
9411-18
Fig. 25 Exhaust Pipe Mounting

(3) Tighten the clamp nuts to 43 N-m (32 ft. lbs.)
torque.
HEAT
SHIELD J9411-14 (4) Install the exhaust pipe support clamps and
nuts. Tighten the nuts to 54 N-m (40 ft. lbs.) torque.
Fig, 24 Left Engine Exhaust Manifold (5) Lower the vehicle.
and stud bolts in the proper position. (Fig. 24) and exhaust system contact with the body panels.
Tighten the bolts to 22 N-m (18 ft. lbs.) torque. Adjust the alignment, i f needed.
(2) Right . exhaust manifold—Install the dipstick
bracket to the manifold. CATALYTIC CONVERTERS—DIESEL
(3) Position washers and exhaust heat shields onto
the manifold stud bolts (Fig. 24). Be sure the tabs on REMOVAL
the heat shields are hooked over the top of the (1) Raise and support vehicle.
exhaust gasket. Install the nuts and tighten to 20 (2) Saturate the bolts and nuts with heat valve
N-m (175 in. lbs.) torque. lubricant. Allow 5 minutes for penetration.
(4) Raise and support the vehicle. (3) Remove clamps and nuts (Fig. 26).
(5) Assemble exhaust pipe to manifold and secure (4) Remove the catalytic converter.
with bolts. Tighten the bolts to 34 N-m (25 ft. lbs.)
torque. MUFFLER
CATALYTIC
(6) Lower the vehicle. CONVERTER
EXHAUST PIPE™DIESEL CLAMP
REMOVAL
(2) Saturate the bolts and nuts with heat valve
lubricant. Allow 5 minutes for penetration.
(3) Remove the bolts and nuts from the exhaust HANGER ASM
pipe to turbocharger exhaust pipe (Fig. 25). W/CLAMP
(4) Remove the clamp nuts.
(5) Disconnect the exhaust pipe support hanger.
J9411-
INSTALLATION
(1) Connect the exhaust pipe support hangers. Fig. 26 Catalytic Converter
(2) Align the exhaust pipe with the turbocharger INSTALLATION
exhaust pipe and the catalytic converter. Install the (1) Assemble converter and clamps loosely to per
bolts and nuts. Tighten the nuts to 34 N-m (25 ft. mit proper • clearance with exhaust heat shields and
lbs.) torque. underbody parts.
EXHAUST SYSTEM AID INTAKE MANIFOLD 11 - 1 3
(2) Tighten all clamp nuts to 43 N-m (32 ft. lbs.) HANGER
torque.
MUFFLER—DIESEL
REMOVAL
(2) Remove the clamps and nuts.
(3) Disconnect the support hanger (Fig. 27).
(4) Remove the muffler.
Fig. 28 Exhaust Tailpipe HD

(2) Connect the support hangers.
(3) Position the exhaust tailpipe and extension
pipe, i f used, for proper clearance with the underbody
parts.
(4) Tighten all clamp nuts to 43 N-m (32 ft. lbs.)
torque.
HEAT SHIELDS—DIESEL
Fig. 27 Muffler
REMOVAL
INSTALLATION
(1) Connect the support hanger. (2) Remove the nuts or bolts holding the exhaust
(2) Install the clamps and nuts. Tighten the nuts heat shield to the floor pan, crossmember or bracket.
to 43 N-m (32 ft. lbs.) torque. (3) Slide the shield out around the exhaust system.
(4) Start the engine and inspect for exhaust leaks INSTALLATION
and exhaust system contact with the body panels. (1) Position the exhaust heat shield to the floor
Adjust the alignment, i f needed. pan, crossmember or bracket and install the nuts or
bolts.
EXHAUST TAILPIPE—DIESEL (2) Tighten the nuts and bolts.
REMOVAL
(1) Raise and support the vehicle. EXHAUST MANIFOLD—DIESEL
(2) Saturate the clamp nuts with heat valve lubri
cant. Allow 5 minutes for penetration. REMOVAL
^ (3) Disconnect the exhaust tailpipe support hanger (1) Disconnect the air intake and exhaust pipes
(Fig. 28). I f used, disconnect the extension pipe sup (Fig. 29).
port hanger (Fig. 27). (2) Disconnect the turbocharger oil supply line and
(4) Remove clamps and nuts (Fig. 28). the oil drain tube from the turbocharger (Fig. 30).
(5) Remove the exhaust tailpipe and extension (3) Disconnect the charge air cooler (Intercooler)
pipe, i f used. inlet duct from the turbocharger (Fig. 30).
(4) Remove the turbocharger and gasket.
INSTALLATION
(5) Remove the cab heater supply and return lines.
(1) Loosely assemble exhaust tailpipe and exten (6) Remove the engine exhaust manifold and gas
sion pipe, i f used, to permit proper alignment of all kets (Fig. 31).
parts. (7) Clean the sealing surfaces.
11 - 1 4 EXHAUST SYSTEM AND INTAKE MANIFOLI mm
REMOVAL A N D INSTALLATION (Continued!
Fig. 31 Engine Exhaust Manifold and Gaskets

EXHAUST
Fig. 29 Air intake Pipe, Exhaust Pipe and

Turbocharger
Fig. 32 Engine Exhaust Manifold Bolt Tightening

Sequence
(2) Install the turbocharger. Apply anti-seize to the
studs and then tighten the turbocharger mounting
nuts to 32 N-m (24 ft. lbs.) torque.
(3) Position the charge air cooler (intercooler) inlet
duct to the turbocharger. With the clamp in position,
tighten the clamp nut to 8 N-m (72 in. lbs.) torque.
(4) Position the air intake pipe and the exhaust
pipe onto the turbocharger. Tighten the clamps to 8
(5) Install the oil drain tube and oil supply line to
the turbocharger. Tighten the drain tube bolts to 24
Fig. 30 Oii Supply Line and Charge Air Cooler N-m (18 ft. lbs.) torque. Tighten the oil supply line
(Intercooler) inlet Duct fitting nut to 15 N-m (11 ft. lbs.) torque.
INSTALLATION!
(6) Connect the cab heater supply and return
(1) Install the engine exhaust manifold and gas lines. Tighten the line nuts to 24 N-m (18 ft. lbs.)
kets use anti-seize on capscrews. Tighten the exhaust torque.
manifold bolts in sequence to 43 N-m (32 ft. lbs.) (7) Operate the engine to check for leaks.
torque (Fig. 32).

INTAKE MANIFOLD COVER—AIR INTAKE HEATER AIR INTAKE
HEATER POWER
REMOVAL GASKET SUPPLY LINES
(1) Remove the charge air cooler (intercooler) out
let duct from the air inlet housing (Fig. 33).
CLAMP VALVE COVER
INTERCOOLER
INLET DUCT
MANIFOLD AIR INTAKE
INTAKE COVER - HEATER
CLAMP- MANIFOLD ELEMENTS
BOLTS
COVER
CABLE
i ^MOUNTING
- ^ ^ ^ STUDS (2)
CLAMP
INTERCOOLER
OUTLET DUCT
CLAMP
7
INTAKE
MANIFOLD
FORWARD«
J9509-53
805dd8f
Fig. 33 Intercooler Outlet Duct Fig. 34 Air Intake Heater
(2) Remove air inlet housing. INTAKE MANIFOLD AIR HEATER
(3) Remove the high pressure fuel lines.
(4) Disconnect the air intake heater power supply
lines (Fig. 34).
(5) Disconnect the charge air temperature sensor
from the intake manifold cover.
(6) Disconnect the air temperature switch from the
intake manifold cover.
(7) Remove the manifold intake cover and gasket
(Fig. 35). Keep the gasket material and any other
material out of the air intake.
(8) Clean the sealing surface.
INSTALLATION
(1) Using a new gasket, install the intake manifold
cover.
(2) Connect the air temperature switch to the
intake manifold cover.
(3) Connect the charge air temperature sensor to
the intake manifold cover.
(4) Some of the intake manifold bolt holes are
drilled through and must be sealed. Apply liquid Fig. 35 Manifold Intake Cover
teflon sealant to the bolts. Install the intake manifold (6) Install the air inlet housing. Tighten the air
cover bolts. Tighten the bolts to 24 N-m (18 ft. lbs.) inlet housing bolts to 24 N-m (18 ft. lbs.) torque.
torque. (7) Install and tighten the air intake heater power
(5) Install a new gasket on top of the air intake supply nuts to 14 N-m (10 ft. lbs.) torque.
heater. (8) Position the charge air cooler (intercooler) out
let duct onto the air inlet housing. Tighten the
11 - 1 6 EXHAUST SYSTEM AND INTAKE MANIFOLD BR
charge air cooler (intercooler) outlet duct clamps to 8
(9) Install and bleed the high pressure fuel lines.
Tighten the high pressure fuel line nuts to 2 4 N-m
TURBOCHAiiEi DIESEL
REMOVAL
(2) Disconnect the air intake pipe and exhaust
pipe (Fig. 36).
Fig, 37 Air Cooler (Intercooler) inlet Duct

(2) Install the turbocharger. Tighten the turbo
charger mounting nuts to 32 N-m (24 ft. lbs.) torque.
(3) Use a new gasket and connect the drain line.
Tighten the drain line connection bolts to 24 N-m (18
ft. lbs.) torque.
(4) New turbocharger must be pre-lubricated with
clean engine lubricating oil before start up. Pour
50-60 cc (2-3 ounces) of oil into supply fitting.
WARNING: DO NOT U S E YOUR FINGER TO TURN

THE TURBINE WHEEL.
Fig, 36 Air intake Pipe, Exhaust Pipe and
(5) Rotate the turbine wheel to allow oil to enter
Turbocharger
the turbocharger.
(3) Remove the oil drain tube bolts. (6) Install the oil supply line. Tighten the oil sup
(4) Remove the oil supply line. ply line fitting nut to 15 N-m (11 ft. lbs.) torque.
(5) Disconnect the charge air cooler (intercooler) (7) Position the Charge air cooler (intercooler) inlet
inlet duct from the turbocharger (Fig. 37). duct to the turbocharger. With the clamp in position,
(6) Remove the turbocharger mounting nuts and tighten the clamp nut to 8 N-m (72 in. lbs.) torque.
the turbocharger. (8) Position the air intake pipe and the exhaust
(7) I f the turbocharger is not to be installed imme pipe onto the turbocharger. Tighten the clamps to 8
diately, cover the opening to prevent material from N-m (72 in. lbs.) torque.
entering into the manifold. (9) Connect the negative cable to the battery.
(8) Clean and inspect the sealing surface. (10) Operate the engine and check for leaks.
CAUTION: The turbocharger is a precision piece of WASTEGATE ADJUSTMENT
equipment and should only be repaired by an The wastegate turbocharger provides additional
authorized facility. Disassembly is not recom low speed boost without over-boost at high speeds.
mended, a s engine/turbo failure could result. This increases low speed torque and better driveabil-
ity.
Proper adjustment of the wastegate assembly is
INSTALLATION
critical to the operation of the wastegate turbo
(1) Install a new gasket and apply anti-seize com
charger (Fig. 38). The control rod is set at the factory
pound to the mounting studs.
BR EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 1 7
and no adjustment should be necessary, unless (2) Apply 133 kPa (19.3 psi) air pressure to the
wastegate assembly is damaged. actuator. The control rod should move 0.33 - 1.27 mm
(0.013 - 0.050 in) total travel. I f the rod travel is out
TURBOCHARGER
of limits, the wastegate linkage must be adjusted.
(3) To adjust the wastegate linkage, apply air pres
sure to the actuator to release the spring tension on
the lever. Remove the control rod from the wastegate
lever (Fig. 40). Pull the wastegate lever toward the
actuator (closed position).
(4) Adjust the length of the clevis end of the con
trol rod to align the clevis pin hole to the wastegate
lever. Install the adjusting link and retaining clip
(Fig. 40).
CAUTION: DO NOT pull, push or force the align

ment of the clevis pin.
(5) After the adjustment is complete, tighten the

actuator rod jam nut.
(6) Recheck the travel on the wastegate control
rod. Adjust, i f necessary.
WASTEGATE
ACTUATOR
CONTROL
ROD J941M5
Fig. 38 Wastegate Turbocharger

CAUTION; DO NOT adjust the wastegate so that
higher pressures are required to open the waste-
gate valve. The turbocharger speed will be
increased and can cause damage to the turbo
charger and cause a loss of engine performance.
(1) Connect regulated air pressure to the waste-

gate actuator (Fig. 39). Install a dial indicator to
measure the control rod movement. Apply 103 - 138 WASTEGATE ACTUATOR J941H7
kPa ( 1 5 - 2 0 psi) to seat the components and take
any slack out of the control rod. Release the air pres Fig. 40 Adjustment of Wastegate Actuator
sure and zero the dial indicator gauge.
INTERCOOLER—DIESEL
REMOVAL
WARNING: IF T H E ENGINE WAS JUST TURNED

OFF, THE INTAKE AND OUTLET DUCTS MAY B E
HOT.
(1) Remove the grille (refer to Group 23, Body for

(2) Remove the front support bracket (Fig. 41).
(3) I f the vehicle is equipped with air conditioning,
remove the condenser as follows:
(a) Discharge the air conditioning system (refer
DIAL
REGULATED to Group 24, Heating and Air Conditioning for the
AIR PRESSURE
INDICATOR J9411-16 proper procedures).
(b) Remove the bolt from the sealing plate.
Fig. 39 Wastegate and Dial Indicator (c) Remove the nuts holding the condenser to
the charge air cooler (intercooler). Lift the con-
denser and sealing plate assembly away from the (3) I f the vehicle is equipped with air conditioning,
charge air cooler (intercooler). install the condenser as follows:
(a) Position the condenser and sealing plate
assembly onto the charge air cooler (intercooler)
studs. Install the nuts and tighten.
(b) Connect the halves of the sealing plate.
Install the bolt and tighten.
(c) Charge the air conditioning system (refer to
Group 24, Heating and Air Conditioning for the
proper procedures).
(4) Install the front support bracket. Install and
tighten the bolts.
(5) Install the grille (refer to Group 23, Body for
EXHAUST PIPE
Fig. 41 Condenser and Charge Air Cooier—
intercooler INSPECTION
(4) Remove the inlet and outlet ducts from the Discard rusted clamps, broken or worn supports
charge air cooler (intercooler) (Fig. 42). and attaching parts. Replace a component with orig
(5) Remove the charge air cooler (intercooler) bolts. inal equipment parts, or equivalent. This will assure
Pivot the charge air cooler (intercooler) forward and proper alignment with other parts in the system and
up to remove. provide acceptable exhaust noise levels.
CLEANING
Clean ends of pipes to assure mating of all parts.
INTAKE MANIFOLD
CLEANING INTAKE
Clean manifold in solvent and blow dry with com
pressed air.
The plenum pan rail must be clean and dry (free of
all foreign material).
mSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straightedge.
EXHAUST MANIFOLD
CLEANING
J9509-53
Clean mating surfaces on cylinder head and mani
Fig. 42 Charge Air Cooler Intercooler Ducts fold. Wash with solvent and blow dry with com
pressed air.
INSTALLATION
(1) Position the charge air cooler (intercooler). INSPECTION
Install the bolts and tighten to 2 N-m (17 in. lbs.) Inspect manifold for cracks.
torque. Inspect mating surfaces of manifold for flatness
(2) Install the inlet and outlet ducts to the charge with a straight edge. Gasket surfaces must be flat
air cooler (intercooler). With the clamps in position, within 0.2 mm per 300 mm (0.008 inch per foot).
tighten the clamp nut to 8 N-m (72 in. lbs.) torque.
CLEANING A N D INSPECTION ( C o n t i n u e d )
INTERCOOLER—CHARGE AIR COOLER CLEANING
Clean ends of pipes and muffler to assure a good
CLEANING seal at mating surfaces.
If the engine experiences a turbocharger failure or
any other occasion where oil or debris is put into the
charge air cooler, the charge air cooler must be ADJUSTMENTS
cleaned.
(1) Remove the charge air cooler from the vehicle, WASTEGATE ADJUSTMENT
refer Charge Air Cooler in this section. The wastegate turbocharger provides additional
(2) Flush the charge air cooler internally with a low speed boost without over-boost at high speeds.
non caustic solvent in the opposite direction of nor This increases low speed torque and better driveabil-
mal air flow. Shake the charge air cooler and ity.
L I G H T L Y tap on the end tanks with a rubber mallet
Proper adjustment of the wastegate assembly is
to dislodge trapped debris. Continue flushing until critical to the operation of the wastegate turbo
all debris or oil is removed. charger (Fig. 43). The control rod is set at the factory
(3) Use a flashlight and mirror to visually inspect and no adjustment should be necessary, unless
the charge air cooler for internal debris. wastegate assembly is damaged.
CAUTION: If internal debris cannot be removed,

scrap the charge air cooler. DO NOT USE CAUSTIC
CLEANERS TO CLEAN THE CHARGE AIR COOLER.
DAMAGE TO THE CHARGE AIR COOLER WILL
RESULT.
(4) After the charge air cooler has been thoroughly

cleaned of all oil and debris with the non caustic sol
vent, wash the charge air cooler internally with hot
soapy water to remove the remaining solvent.
(5) Rinse thoroughly with clean water.
(6) Blow compressed air into the charge air cooler
in the opposite direction of normal air flow until the
charge air cooler is dry internally.
INSPECTION
(1) Visually inspect the charge air cooler
(2) Inspect the tubes, fins and welds for tears,
breaks or other damage. I f any damage causes the
charge air cooler to fail, the charge air cooler must
replaced.
Fig. 43 Wastegate Turbocharger
CATALYTIC CONVERTOR
CAUTION: DO NOT adjust the wastegate so that
INSPECTION higher pressures are required to open the waste-
Look at the stainless steel body of the catalytic, gate valve. The turbocharger speed will be
inspect for bulging or other distortion that could be a increased and can cause damage to the turbo
result of overheating. I f the catalytic has a heat charger and cause a loss of engine performance.
shield attached make sure i t is not bent or loose.
(1) Connect regulated air pressure to the waste-
WARNING: UNLEADED FUEL MUST BE USED TO gate actuator (Fig. 44). Install a dial indicator to
PREVENT BLOCKAGE OR CONTAMINATION TO measure the control rod movement. Apply 103 - 138
THE CATALYST CORE. kPa (15 - 20 psi) to seat the components and take
any slack out of the control rod. Release the air pres
I f you suspect internal damage to the catalyst, tap sure and zero the dial indicator gauge.
ping the bottom of the catalyst with a rubber mallet (2) Apply 133 kPa (19.3 psi) air pressure to the
may indicate a damaged core. actuator. The control rod should move 0.33 - 1.27 mm
(0.013 - 0.050 in) total travel. I f the rod travel is out
of limits, the wastegate linkage must be adjusted.
11-20 EXHAUST SYSTEM AND INTAKE MANIFOLD BR
CAUTION: DO NOT pull, push or force the align
ment of the clevis pin.
(5) After the adjustment is complete, tighten the

actuator rod j a m nut.
(6) Recheck the travel on the wastegate control
rod. Adjust, i f necessary.
CONTROL
ROD
DIAL REGULATED
INDICATOR AIR PRESSURE J9411-16
Fig, 44 Wastegate and Dial Indicator

(3) To adjust the wastegate linkage, apply air pres
sure to the actuator to release the spring tension on
the lever. Remove the control rod from the wastegate
lever (Fig. 45). P u l l the wastegate lever toward the WASTEGATE ACTUATOR J9411-17
actuator (closed position).
(4) Adjust the length of the clevis end of the con Fig. 45 Adjustment of Wastegate Actuator
trol rod to align the clevis pin hole to the wastegate
lever. I n s t a l l the adjusting l i n k and retaining clip
(Fig. 45).
_R EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 21
SPECIFICATIONS
TURBOCHARGER SPECIFICATIONS
COMPONENT DIMENSIONS
................ 635 mm Water (25 in. Water) Max.
Turbo Radial Clearance 0.300-0.460 mm (0.012-0.018 inch)
Turbo Rotor Assembly End Play
Before S/N 840638 .......... 0.102-0.152 mm (0.004-0.006 inch)

S/N 840638 AND AFTER 0.026-0.076 mm (0.001-0.003 inch)
J9511-23
Adjusting Strap Bolt 23 N®m (200 in. lbs.] Intake Manifold Capbolts Refer to Procedure in
Air Heater Power Supply Nuts. 14N-m(10ft. lbs.) Service Manual.
Intake Manifold Cover Bolts.. 24 N-m (18 ft. lbs.)
Cab Heater Supply/Return Line Nuts. 24N»m(18ft. lbs.) Intercooler Attaching Bolts.... 2N-m(17in. lbs.)
Catalytic Converter-to-Muffler Intercooler Duct Clamp Nuts. 8 N-m (72 in. lbs.)
Clamp Nuts 43 N-m (32 ft. lbs.)
Muffler-to-Tail Pipe Clamp Nuts 43 N-m (32 ft. lbs.)
Exhaust Manifold-to-Cylinder
Head Bolts (5.9L Diesel) 43 N-m (32 ft. lbs.) Throttle Control Bracket
Exhaust Pipe-to-Catalytic Mounting Bolts 24 N-m (18 ft. lbs.)
Converter Clamp Nuts 43 N-m (32 ft. lbs.) Turbocharger Mounting Nuts 32 N-m (24 ft. lbs.)
Exhaust Pipe-to-Exnaust Turbocharger Oil Drain Tube Bolts 24 N-m (18 ft. lbs.)
Manifold Bolts/Nuts 26 N-m (19 ft. lbs.) Turbocharger Oil Supply Line Fitting Nut. 1 5 N - m ( l l ft. lbs.)
Turbocharger V-Bana Clamp 8.5 N-m (75 in. lbs.)
Fuel Heater Ground Bolt.. 12 N-m (110 in. lbs.
Fuel Line Nuts 24 N-m (18 ft. lbs.)
Generator Mounting Bolt 41 N-m (30 ft. lbs.]
J9511-24
FRAME AND BUMPERS 13 -1
FRAME AND BUMPERS
CONTENTS
page page
BUMPERS .. 1 FRAME .. 4
BUMPERS
INDEX
page page
GENERAL INFORMATION FRONT BUMPER LOWER FASCIA 2

FRAME COATINGS INFORMATION 1 FRONT BUMPER UPPER FASCIA 1
REMOVAL AND INSTALLATION FRONT BUMPER 1
FRONT BUMPER AIR DAM 2 REAR BUMPER . 3
GENERAL I N F O R M A T I O N R E M O V A L AMD I N S T A L L A T I O N
FRAME COATINGS INFORMATION FRONT BUMPER
CAUTION: Depending on the vehicle build location, REMOVAL

there are two different coatings applied to BR (1) Support front bumper on a suitable lifting
frames: device.
(2) Remove bolt holding front bumper brace to
11th frame rail (Fig. 1).
VEHICLE
POSITION FRAME (3) Remove nuts and stud plates holding front
BUILD bumper to end of frame rail.
VIN COATING
LOCATION (4) Disengage wire connectors from horns.
CHARACTER
(5) Disengage wire connectors from fog lamps, i f
St. Louis North J E-Coat equipped.
Dodge City S Wax Coat (6) Separate front bumper from vehicle.
INSTALLATION
Lago Alberto M Wax Coat Reverse the preceding operation.
Mexico
FRONT BUMPER UPPER FASCIA
frame attached components may vary depending on REMOVAL
frame coatings. Ensure the replacement fastener is (1) Remove bumper.
designed for the specific frame coating. Refer to the (2) Disengage clips holding upper fascia to bumper
Torque Specifications Chart at the end of each face bar (Fig. 2).
group to determine the correct torque value. (3) Separate fascia from bumper.
INSTALLATION
Reverse the preceding operation.
13 - 2 FRAME A I D BUMPERS ^ _ — — — BR
REMOVAL AND I N S T A L L A T I O N {Continued)

INSTALLATION
Fig. 1 Front Bumper

J9413-2
RETAINING UPPER
Fig. 3 Front Bumper Lower Fascia
FRONT BUMPER AIR 0AM
REMOVAL
(1) Remove Pin-type fasteners holding air dam to
bottom of front bumper (Fig. 4).
(2) Remove screws holding air dam to bottom of
front bumper.
(3) Separate air dam from vehicle.
LOWER RETAINING
FASCIA CUP J9413-3
Fig. 2 Front Bumper Upper Fascia

FRONT BUMPER LOWER FASCIA
REMOVAL
(1) Remove bumper.
(2) Disengage clips holding end of upper fascia to
bumper face bar (Fig. 3).
(3) Disengage clips holding lower fascia to bumper
face bar.
(4) Separate lower fascia from bumper.
mm FRAME AND BUMPERS 13 - 3

INSTALLATION REAR BUMPER
REMOVAL
BUMPER
(1) Support rear bumper on a suitable lifting
device.
(2) Remove bolts holding rear bumper braces to
frame rails (Fig. 5).
(3) Disengage license plate lamp wire connector
from body wire harness, i f equipped.
(4) Separate rear bumper from vehicle.
INSTALLATION
AIR DAM SCREW
Fig. 4 Front Bumper Air Dam
Fig. 5 Rear Bumper

13 - 4 FRAME AND BUMPERS
FRAME
page page
G E N E R A L INFORMATION SPARE TIRE WINCH 6

FRAME COATINGS INFORMATION 4 TRAILER HITCH . ..................... 6
GENERAL INFORMATION 4 TRANSFER C A S E SKID PLATE . 6
SERVICE PROCEDURES SPECIFICATIONS
FRAME SERVICE 5 TORQUE SPECIFICATIONS 10
REMOVAL AND INSTALLATION VEHICLE DIMENSIONS . 7
CAB CHASSIS ADAPTER BRACKET 6

frames:
11th
VEHICLE
POSITION FRAME
BUILD
VIN COATING
LOCATION
CHARACTER
Lago Alberto M Wax Coat
Mexico

frame attached components may vary depending on
GENERAL INFORMATION
BR trucks have a ladder-type frame (Fig. 1) with
Box-section front rails, dropped center section and
open-channel side rails in the rear.
Cross members attached to the frame side rails
with rivets, welds or bolts form a ladder-type con
struction (Fig. 1). The cab is isolated from the frame
Fig. 2 Cab Mounts
with rubber load cushions (Fig. 2) with through-bolts.
The cargo box or bed is attached to the frame with ing and road surface variances without bending when
bolts. Refer to Group 23, Body for cargo box service subjected to normal driving conditions. The frame is
procedures. the mounting platform for the following systems and
The frame is designed to absorb and dissipate flex components:
ing and twisting due to acceleration, braking, corner- • Front and rear suspension systems.
• Engine, transmission, and transfer case.
• Steering gear and linkage.
FRAME AND BUMPERS 13 - 5
mm
• Exhaust system and heat shields. Welding the joints around riveted cross members
• Fuel cell and fuel line tubing. and frame side rails is not recommended.
• Front end sheet metal and radiator closure A straightening repair process should be limited to
panel. frame members that are not severely damaged. The
• Skid plate. replacement bolts, nuts and rivets that are used to
• Passenger cab. join the frame members should conform to the same
• Cargo box or bed. specifications as the original bolts, nuts and rivets.
• Spare tire winch.
• Front and rear bumper systems. FRAME REPAIRS
DRILLING HOLES
SERVICE PROCEDURES Do not drill holes in frame side rail top and bottom
flanges, metal fatigue can result causing frame fail
FRAME SERVICE ure. Holes drilled in the side of the frame rail must
be at least 38 mm (1.5 in.) from the top and bottom
S A F E T Y PRECAUTIONS AND WARNINGS flanges.
Additional drill holes should be located away from
WARNING: USE EYE PROTECTION WHEN GRIND
existing holes.
ING OR WELDING METAL, SERIOUS EYE INJURY
CAN RESULT, BEFORE PROCEEDING WITH FRAME WELDING
REPAIR INVOLVING GRINDING OR WELDING, VER
Use MIG, TIG or arc welding equipment to repair
IFY THAT VEHICLE F U E L SYSTEM IS NOT LEAKING
welded frame components.
OR IN CONTACT WITH REPAIR AREA, PERSONAL
Frame components that have been damaged should
INJURY CAN RESULT. DO NOT ALLOW OPEN
be inspected for cracks before returning the vehicle
FLAME TO CONTACT PLASTIC BODY PANELS.
to use. I f cracks are found in accessible frame com
FIRE OR EXPLOSION CAN RESULT. WHEN
ponents perform the following procedures.
WELDED FRAME COMPONENTS A R E R E P L A C E D ,
(1) Drill a hole at each end of the crack with a 3
100% PENETRATION WELD MUST BE ACHIEVED
mm (0.125 in.) diameter drill bit.
DURING INSTALLATION. IF NOT, DANGEROUS
(2) Using a suitable die grinder with 3 inch cut off
OPERATING CONDITIONS CAN RESULT. STAND
wheel, V-groove the crack to allow 100% weld pene
C L E A R O F C A B L E S OR CHAINS ON PULLING
tration.
EQUIPMENT DURING FRAME STRAIGHTENING
(3) Weld the crack.
OPERATIONS, PERSONAL INJURY CAN RESULT.
(4) I f necessary when a side rail is repaired, grind
DO NOT VENTURE UNDER A HOISTED VEHICLE
the weld smooth and install a reinforcement channel
THAT IS NOT SUPPORTED ON S A F E T Y STANDS,
(Fig. 3) over the repaired area.
PERSONAL INJURY CAN RESULT.
NOTE: If a reinforcement channel is required, the
top and bottom flanges should be 0.250 inches nar
CAUTION: Do not reuse damaged fasteners, qual
rower than the side rail flanges. Weld only in the
ity of repair would be suspect. Do not drill holes in
areas indicated (Fig. 3).
top or bottom frame rail flanges, frame rail failure
can result. Do Not use softer than Grade 3 bolts to
replace production fasteners, loosening or failure FRAME FASTENERS
can result. When using heat to straighten frame Bolts, nuts and rivets can be used to repair frames
components do not exceed 566°C (1050°F), metal or to install a reinforcement section on the frame.
fatigue can result. Welding the joints around riveted Bolts can be used in place of rivets. When replacing
cross members and frame side rails can weaken rivets with bolts, install the next larger size diameter
frame. bolt to assure proper fit. I f necessary, ream the hole
out just enough to sufficiently receive the bolt.
FRAME STRAIGHTENING
Conical-type washers are preferred over the split-
ring type lock washers. Normally, grade-5 bolts are
When necessary, a conventional frame that is bent
adequate for frame repair. Grade-3 bolts or softer
or twisted can be straightened by application of heat.
should not be used. Tightening bolts/nuts with the
The temperature must not exceed 566°C (1050°F).
correct torque, refer to the Introduction Group at the
The metal will have a dull red glow at the desired
front of this manual for tightening information.
temperature. Excessive heat will decrease the
strength of the metal and result in a weakened
frame.
13 - 6 F i A i E AND BUMPERS BR
Fig. 5 Cab Chassis Adapter Bracket—Rear

Fig. 3 Frame Reinforcement
(3) Separate skid plate from vehicle.
INSTALLATION
CAB CHASSIS ADAPTER BRACKET (1) Position skid plate on vehicle.
(2) Install bolts holding skid plate to frame rails.
REMOVAL (3) Remove safety stands and lower vehicle.
(1) Remove nuts attaching cab chassis adapter
bracket to frame rail (Fig. 4) and (Fig. 5).
(2) Separate cab chassis adapter bracket from
frame rail
Fig. 6 Skid Plate

SPARE TIRE WINCH
Fig. 4 Cab Chassis Adapter Bracket—Front REMOVAL

(1) Remove spare tire from under vehicle.
INSTALLATION
(2) Remove bolts holding spare tire winch to spare
(1) Position cab chassis adapter bracket on frame tire bracket (Fig. 7).
rail (3) Separate spare tire winch from vehicle.
(2) Install nuts attaching cab chassis adapter
bracket to frame rail. INSTALLATION
(1) Position spare tire winch on vehicle.
TRANSFER CASE SKID PLATE (2) Installe bolts holding spare tire winch to spare
tire bracket.
REMOVAL
(3) Install spare tire.
(1) Hoist and support vehicle on safety stands.
(2) Remove bolts holding skid plate to frame rails
(Fig. 6).
BR FRAME AND BUMPERS 13-7

TRAILER HITCH
REMOVAL
(1) Support trailer hitch on a suitable lifting
device.
(2) Remove fasteners holding trailer wiring con
nector to trailer hitch, i f equipped.
(3) Remove bolts holding trailer hitch to frame
rails (Fig. 8).
(4) Separate trailer hitch from vehicle.
INSTALLATION
(1) Position trailer hitch on vehicle.
(2) Install the bolts holding trailer hitch to frame
rails and remove lifting device.
(3) Install fasteners holding trailer wiring connec
tor to trailer hitch, i f equipped.
SPECIFICATIONS '
VEHICLE DIMENSIONS
Frame dimensions are' listed in inch scale. A l l
Fig. 7 Spare Tire Winch
dimensions are from center to center of Principal
Locating Point (PLP), or from center to center of PLP
and fastener location (Fig. 9), - (Fig. 10), (Fig. 11),
(Fig. 12) and (Fig. 13).
HITCH
Fig. 8 Trailer Hitch

801834a6
Fig. 9 Frame Dimensions m

39
BR — — — FRAME AND BUMPERS 13 - 9
^Measurements are in Millimeters (mm).
LENGTH DIMENSIONS FOR DIFFERING WHEELBASES*
LENGTH LENGTH LENGTH

WHEELBASE
A B C
118 2118.0 3663.6 4185.4
134 2118.0 3994.5 4693.4
138 2626.0 4096.1 4693.4
154 2626.0 4502.5 5201.4
162 2118.0 4705.0 5042.5
A. & B. U P P E R C O R N E R
O F WINDSHIELD OPENING LH SIDE VIEW
TO TOP O F RADIUS AT L O W E R
C O R N E R O F OPENING. 8031586c
A. Centerline of A-Pa
lir gaging holetocenterline of seat belt retractor hole at B-Pa
lir.
B. Centerline of radius at rear lower door opening flange inner edge to center of radius
at cowl flange edge.
Fig. 10 Body Dimensions—Front View C . Centerline of radius at front lower door opening flange inner edge to center of radius
at upper opening rear flage inner edge.
D. Centerline of radius at rear lower door opening flange inner edge to center of radius
at upper front flange inner edge.
803f586f
Fig. 11 Body Dimensions—Conventional Cab

13 - 10 FRAME AND BUMPERS BR
WAX COATED FRAME
DESCRIPTION TORQUE
Cab Chassis adapter nut 108 N-m (80 ft. lbs.)
Front bumper brkt-to-frame nut. .68 N-m (50 ft. lbs.)
Front bumper outer brace bolt . . .68 N-m (50 ft. lbs.)
Rear bumper-to-brace nut .40 N-m (30 ft. lbs.)
Rear bumper brace-to-brkt nut. .101 N-m (75 ft. lbs.)
Rear bumper brkt-to-frame nut .101 N-m (75 ft. lbs.)
Skid plate crossmember-to-
frame bolt . . . . . . . . . . . . . 54 N-m (40 ft. lbs.)
D. 1235.4 MM G. 436.2 MM Skid plate-to-skid plate
A. 1284.8 MM
B. 1190.3 MM E . 582.6 MM H. 440.5 MM crossmember bolt. 40 N-m (30 ft. lbs.)
C. 1546.3 MM F. 538.8 MM J. 4 2 a 8 ~ M M | Skid plate-to-trans crossmember
LH S I D E VIEW bolt 54 N-m (40 ft. lbs.)
A- Cene tnirle of A-Pa lir gagnig hoel to centen Spare tire winch bolt . . . . . . . . . .27 N-m (20 ft. lbs.)
rile of seat betl retractor hoel at B-Pa lir.
B. C e
n e
t r o f ra d ui s a t re ar do or op
e n
nig al
fnge n
iner edg e c
e ne
tr
Trailer hitch nuto f r
adu
is 88 N-m (65 ft. lbs.)
C. aCtece
o wo l falfnragdeuisedagtef.ront olwer door opennig alfnge niner edge to cene
lower to
un
ptre
p r o pra
en nu
iigs at a lfn
g eolwnienrerdoeodrge.ennig alfnge niner edge to cene tE-COATED
r of raduis FRAME
D. C en
at
etr o f d
rear
upper front alfnge niner edge. re ar op tr of r

a du
i s at
DESCEIPTION TORQUE
E. qLo
uw
ae trrre
re ga a lsrscoornpeernnniign.er alfnge edge to upper front corner niner alfnge eCab dge oChassis
f adapter nut. 108 N-m (80 ft. lbs.)
Lo
F. quw
ae trrfront oco
re glass pre
ne
nnrign.iner alfnge edge to upper rear corner niner alfnge eFront dge of bumper brkt-to-frame nut. .68 N-m (50 ft. lbs.)
Front bumper outer brace bolt . . .68 N-m (50 ft. lbs.)
G. Upper niner alfnge olwer edge to olwer alfnge upper edge of quare tr gRear
alss opbumper-to-brace
ennig. nut. . . . . . .40 N-m (30 ft. lbs.)
8035f86e Rear bumper brace-to-brkt nut. .101 N-m (75 ft. lbs.)
Fig. 12 Body Dimensions—Ciub Cab Rear bumper brkt-to-frame nut .101 N-m (75 ft. lbs.)
Skid plate crossmember-to-frame
bolt . . . . . . . . . . . . . . . . . .54 N-m (40 ft. lbs.)
Skid plate-to-crossmember bolt. . .40 N-m (30 ft. lbs.)
Skid plate-to-trans crossmember
bolt . . . . . . . . . . . . . . 5 4 N-m (40 ft. lbs.)
Spare tire winch bolt . . . . . .27 N-m (20 ft. lbs.)
Trailer hitch nut 108 N-m (80 ft. lbs.)
R E A R VIEW
A. & B. Center of radius at top corner to center of radius at

lower corner of glass mounting flange.
C. Lower edge of upper back glass mounting flange to

upper edge of lower back glass mounting flange
measurement taken at centerline of rear glass opening.
Fig. 13 Body Dimensions—Rear View

FUEL SYSTEM
CONTENTS
page page
FUEL DELIVERY SYSTEM-DIESEL ENGINE . . . 69 FUEL INJECTION SYSTEM-GASOLINE ENGINES 24

FUEL DELIVERY SYSTEM-GASOLINE ENGINE .. 3 GENERAL INFORMATION 1
FUEL INJECTION SYSTEM-DIESEL ENGINE . . 112
INDEX
page page
GENERAL INFORMATION GASOLINE/OXYGENATE BLENDS 2

FUEL REQUIREMENTS 2 INTRODUCTION 1
FUEL REQUIREMENTS—DIESEL ENGINE 2
GENERAL INFORMATION engines), a fuel injection pump (diesel engine), a

mechanical fuel transfer (lift) pump (diesel) and a
INTRODUCTION fuel filter. I t also consists of fuel tubes/lines/hoses
Throughout this group, references are made to par and fittings, vacuum hoses, throttle body and fuel
ticular vehicle models by alphabetical designation or injector(s). The powertrain control module (PCM) will
by the particular vehicle nameplate. A chart showing either directly operate or regulate certain compo
a breakdown of the alphabetical designations is nents of the fuel system. Refer to the Powertrain
included in the Introduction section at the beginning Control Module sections for additional information.
of this manual. The Fuel Delivery System consists of: the elec
All vehicles are equipped with either a 3.9L (V-6) tric fuel pump (gas), fuel injection pump (diesel), fuel
engine, a 5.2L (V-8) engine, two different 5.9L (V-8) transfer pump (diesel), fuel filter, fuel tubes/lines/
engines, two different 8.0L (V-10) engines, or a 5.9L hoses, fuel rail, fuel injectors and fuel pressure regu
Cummins in-line 6 cylinder diesel engine. lator.
• The 3.9L (V-6) and 5.2L (V-8) engines will be A Fuel Return System is used on all vehicles (all
referred to in this group as: LDC (Light Duty Emis engines). On gas powered engines, fuel is returned
sion Cycle) engines. through the fuel pump module and back to the fuel
• The 5.9L (V-8) gas powered engine will be tank. A separate fuel return line from the tank to the
referred to as either: LDC (Light Duty Emission engine is not used on any gas powered engine.
Cycle) or HDC (Heavy Duty Emission Cycle) engine. On diesel powered engines, a separate fuel return
• The 8.0L (V-10) engine will be referred to as line from the tank to the engine is used.
either: MDC (Medium Duty Emission Cycle) or HDC The Fuel Tank Assembly consists of: the fuel
(Heavy Duty Emission Cycle) engine. tank, filler tube, fuel gauge sending unit/electric fuel
• The diesel engine will be referred to as: HDC pump module (electric fuel pump on gas powered
(Heavy Duty Emission Cycle) engine. engines only), a pressure relief/rollover valve and a
Either of the HDC gas powered engines can be eas pressure-vacuum filler cap.
ily identified by the use of an engine mounted air Also to be considered part of the fuel system is the
injection pump. The 3.9L/5.2L/5.9L LDC gas engines Evaporation Control System. This is designed to
or the diesel engine will not use an air injection reduce the emission of fuel vapors into the atmo
pump. sphere. The description and function of the Evapora
The Fuel System consists of: the fuel tank, an tive Control System is found in Group 25, Emission
electric fuel tank mounted fuel pump (gas powered Control Systems.
14 - 2 FUEL SYSTEM BR
FUEL REQUIREMENTS Many gasolines are now being blended that con
Light spark knock at low engine speeds is not tribute to cleaner air, especially in those areas of the
harmful to your engine. However, continued heavy country where pollution levels are high. These new
spark knock at high speeds can cause damage and blends provide a cleaner burning fuel and some are
should be reported to your dealer immediately. referred to as reformulated gasoline.
Engine damage resulting from operating with a Reformulated Gasoline
heavy spark knock may not be covered by the new Many areas of the country are requiring the use of
vehicle warranty. cleaner-burning fuel referred to as Reformulated
In addition to using unleaded gasoline with the Gasoline. Reformulated gasolines are specially
proper octane rating, gasolines that contain deter blended to reduce vehicle emissions and improve air
gents, corrosion and stability additives are recom quality.
mended. Using gasolines, that have these additives Chrysler Corporation strongly supports the use of
will help improve fuel economy, reduce emissions, reformulated gasolines whenever available. Although
and maintain vehicle performance. Generally, pre your vehicle was designed to provide optimum perfor
mium unleaded gasolines contain more additive than mance and lowest emissions operating on high qual
regular unleaded. ity unleaded gasoline, i t will perform equally well
Poor quality gasoline can cause problems such as and produce even lower emissions when operating on
hard starting, stalling, and stumble. I f you experi reformulated gasoline.
ence these problems, try another brand of gasoline Materials Added to Fuel
before considering service for the vehicle. Indiscriminate use of fuel system cleaning agents
should be avoided. Many of these materials intended
GASOLINE/OXYGENATE BLENDS for gum and varnish removal may contain active sol
Some fuel suppliers blend gasoline with materials vents of similar ingredients that can be harmful to
that contain oxygen such as alcohol, MTBE (Methyl fuel system gasket and diaphragm materials.
Tertiary Butyl Ether) and ETBE (Ethyl Tertiary
Butyl Ether). Oxygenates are required in some areas FUEL REQUIREMENTS—DIESEL ENGINE
of the country during winter months to reduce carbon
monoxide emissions. The type and amount of oxygen WARNING: Do not use alcohol or gasoline a s a fuel
ate used in the blend is important. blending agent. They can be unstable under certain
The following are generally used in gasoline conditions and hazardous or explosive when mixed
blends: with diesel fuel.
Ethanol - (Ethyl or Grain Alcohol) properly
Use good quality diesel fuel from a reputable sup
blended, is used as a mixture of 10 percent ethanol
plier i n your Dodge truck. For most year-round ser
and 90 percent gasoline. Gasoline blended with etha
vice, number 2 diesel fuel meeting ASTM
nol may be used in your vehicle.
specification D-975 will provide good performance. I f
Methanol - (Methyl or Wood Alcohol) is used in a
the vehicle is exposed to extreme cold (below 0°F/-
variety of concentrations when blended with
18°C), or is required to operate at colder-than-normal
unleaded gasoline. You may find fuels containing 3
conditions for prolonged periods, use climatized No. 2
percent or more methanol along with other alcohols
diesel fuel or dilute the No. 2 diesel fuel with 50%
called cosolvents.
kerosene or No. 1 diesel fuel. This will provide better
Do not use gasolines containing Methanol.
protection from fuel gelling or wax-plugging of the
Use of methanol/gasoline blends may result in
fuel filters.
starting and driveability problems and damage criti
Diesel fuel is seldom completely free of water. To
cal fuel system components.
prevent fuel system trouble, drain the accumulated
Problems that are the result of using methanol/
water from the fuel/water separator using the fuel/
gasoline blends are not the responsibility of Chrysler
water separator drain provided. I f you buy good-qual
Motors and may not be covered by the new vehicle
ity fuel and follow the cold-weather advice above, fuel
warranty.
conditioners should not be required in your vehicle I f
M T B E / E T B E - Gasoline and MTBE (Methyl Ter
available in your area, a high cetane "premium" die
tiary Butyl Ether) blends are a mixture of unleaded
sel fuel may offer improved cold starting and
gasoline blended and up to 15 percent MTBE. Gaso
warm-up performance
line and ETBE (Ethyl Tertiary Butly Ether) are
blends of gasoline and up to 17 percent ETBE. Gas
oline blended with MTBE or ETBE may be used i n
your vehicle.
BR FUEL SYSTEM 14 - 3
FUEL DELIVERY SYSTEM-6ASOLINE ENGINE
page page
DESCRIPTION AND OPERATION FUEL SYSTEM PRESSURE RELEASE

FUEL DELIVERY SYSTEM 3 PROCEDURE-WITH PRESSURE TEST
FUEL FILTER/FUEL P R E S S U R E REGULATOR . . . 4 PORT . 8
FUEL GAUGE SENDING UNIT 4 FUEL TUBES/LINES/HOSES AND CLAMPS . . . . 10
FUEL INJECTORS—3.9L/5.2L/5.9L ENGINES 5 QUICK-CONNECT FITTINGS . . . . . . . 10
FUEL INJECTORS—8.0L ENGINE 5 REMOVAL AND INSTALLATION
FUEL PUMP MODULE 3 ACCELERATOR PEDAL 21
FUEL PUMP 3 FUEL FILTER/FUEL PRESSURE REGULATOR . . 15
FUEL RAIL—3.9L/5.2L/5.9L ENGINES 5 FUEL INJECTOR RAIL—3.9L/5.2L/5.9L
FUEL RAIL—8.0L ENGINE 6 ENGINES 16
FUEL TANK FILLER TUBE CAP 6 FUEL INJECTOR RAIL—8.0L V-10 ENGINE . . . . 18
FUEL TANK 5 FUEL INJECTOR(S)—ALL GAS ENGINES . . . . . 19
QUICK-CONNECT FITTINGS 6 FUEL LEVEL SENSOR 16
DIAGNOSIS AND TESTING FUEL PUMP INLET STRAINER 16
FUEL GAUGE SENDING UNIT 8 FUEL PUMP MODULE 15
FUEL INJECTORS 8 FUEL PUMP RELAY . 15
FUEL PUMP P R E S S U R E TEST-ALL ENGINES FUEL TANK—ALL ENGINES 19
WITHOUT P R E S S U R E T E S T PORT 7 THROTTLE CABLE . 22
FUEL PUMP P R E S S U R E TEST—ALL ENGINES SPECIFICATIONS
WITH P R E S S U R E T E S T PORT 6 FUEL SYSTEM PRESSURE 23
SERVICE PROCEDURES FUEL TANK CAPACITY 23
FUEL SYSTEM P R E S S U R E R E L E A S E TORQUE SPECIFICATIONS 23
PROCEDURE—WITHOUT P R E S S U R E T E S T VECI LABEL SPECIFICATIONS . . . . . . . . . . . . . 23
PORT 10
DESCRIPTION AND OPERATION FUEL P U i P MODULE

The fuel pump module on all gas powered engines
FUEL DELIVERY SYSTEM is installed in the top of the fuel tank (Fig. 1). The
The fuel delivery system consists of: the electric fuel pump module (Fig. 1) or (Fig. 2) contains the fol
fuel pump, fuel filter/fuel pressure regulator, fuel lowing:
tubes/lines/hoses, fuel rail, fuel injectors, fuel tank, • A combination fuel filter/fuel pressure regulator
accelerator pedal and throttle cable. • Electric fuel pump
A fuel return system is used on all models (all gas • Fuel pump reservoir
powered engines). Fuel is returned through the fuel © A separate in-tank fuel filter
pump module and back into the fuel tank through © Pressure relief/rollover valve
the fuel filter/fuel pressure regulator. A separate fuel • Fuel gauge sending unit
return line from the engine to the tank is no longer • Fuel supply line connection
used with any gas powered engine. • Auxiliary fuel supply fitting (not all engines)
The fuel tank assembly consists of: the fuel tank,
filler tube, fuel gauge sending unit/electric fuel pump FUEL P U i P
module, a pressure relief/rollover valve and a pres The fuel pump used in this system has a perma
sure-vacuum filler cap. nent magnet electric motor. The pump is part of the
Also to be considered part of the fuel system is the fuel pump module (Fig. 1). The fuel pump module is
evaporation control system. This is designed to suspended in fuel in the fuel tank. Fuel is drawn in
reduce the emission of fuel vapors into the atmo through a filter and pushed through the electric
sphere. The description and function of the Evapora motor to the outlet. The pump contains a check
tive Control System is found in Group 25, Emission valve. This valve is located near the pump outlet. It
Control Systems. restricts fuel movement in either direction to main
tain fuel supply line pressure when the pump is not
DESCRIPTION AMD OPERATION {Continued)

PLASTIC FUEL FILTER/ FUEL pose of this feature is to prevent a false setting of
LOCKNUT FUEL PRESSURE SUPPLY TOP OF misfire and fuel system monitor trouble codes i f the
REGULATOR CONNECTION FUEL TANK
fuel level in the tank is less than 15 percent of its
rated capacity. This switch is mounted in the fuel
reservoir within the fuel pump module
PRESSURE RELIEF/ FUEL FILTER/FUEL PRESSURE REGULATOR

ROLLOVER VALVE
A combination fuel filter and fuel pressure regula
tor is used on all engines. I t is pressed into a rubber
grommet located on the top of the fuel pump module
(Fig. 3). A separate frame mounted fuel filter is not
PUMP/GAUGE used with any engine.
AUXILIARY ELEC. CONNECTION Fuel Pressure Regulator Operation: The pres
FUEL SUPPLY
FITTING sure regulator is a mechanical device that is not con
(SOME ENGINES) J9414-32 trolled by engine vacuum or the powertrain control
module (PCM).
Fig. 1 Top View Fuel Pump Module—Gas Powered The regulator is calibrated to maintain fuel system
Engines—Typical operating pressure of approximately 339 kPa ± 34
kPa (49.2 psi ± 5 psi) at the fuel injectors. I t con
FUEL G A U G E LOCKING
FLOAT SENDING UNIT TABS
tains a diaphragm, calibrated springs and a fuel
ELECTRIC return valve. The internal fuel filter (Fig. 3) is also
FUEL PUMP part of the assembly.
INTERNAL
FUEL FILTER
MOUNTING IN-TANK
SCREWS FUEL FILTER J9414-33
Fig. 2 Fuel Pump Module Components—Gas RUBBER FUEL FILTER/FUEL

GROMMET PRESSURE REGULATOR
Powered Engines—Typical
AT PUMP
operational. Voltage to operate the pump is supplied MODULE
through the fuel pump relay.
CALIBRATED
FUEL GAUGE SENDING UNIT SPRINGS X EXCESS FUEL BACK
The fuel gauge sending unit is attached to the side TO TANK
of the fuel pump module. The sending unit consists of FUEL INLET J9314-170
a float, an arm, and a variable resistor (track). The
track is used to send an electrical signal for fuel Fig. 3 Side View—Filter/Regulator
gauge operation.
Fuel is supplied to the filter/regulator by the elec
As the fuel level increases, the float and arm move tric fuel pump through an opening tube at the bot
up. This decreases the sending unit resistance, caus tom of filter/regulator (Fig. 3).
ing the fuel gauge on the instrument panel to read The fuel pump module contains a check valve to
full. As the fuel level decreases, the float and arm
maintain some fuel pressure when the engine is not
move down. This increases the sending unit resis
operating. This will help to start the engine.
tance, causing the fuel gauge on the instrument
If fuel pressure at the pressure regulator exceeds
panel to read empty.
approximately 49.2 psi, an internal diaphragm closes
A reed type switch is also used to monitor fuel and excess fuel pressure is routed back into the tank
level in fuel tank. An electrical signal is sent to the
through the pressure regulator. A separate fuel
PCM from this switch to indicate fuel level. The pur
return line is not used with any engine.
BR FUEL S Y S T E i 14 - 5

FUEL TANK switching the ground path to each individual injector
All models pass a full 360 degree rollover test on and off. Injector pulse width is the period of time
without fuel leakage. To accomplish this, fuel and that the injector is energized. The PCM will adjust
vapor flow controls are required for all fuel tank con injector pulse width based on various inputs i t
nections. receives.
All models have a pressure relief/rollover valve
mounted in the top of the fuel tank. FUEL INJECTORS—8.0L ENGINE
An evaporation control system is used to reduce The fuel injectors are attached to the fuel rail (Fig.
emissions of fuel vapors into atmosphere by evapora 5). Ten individual injectors are used on the 8.0L
tion and to reduce unburned hydrocarbons emitted V-10 engine.
by vehicle engine. When fuel evaporates from fuel ELECTRICAL MOUNTING
tank, vapors pass through vent hoses or tubes to a CONNECTOR BOLTS (6)
charcoal canister. The are temporarily held in the
canister. When the engine is running, the vapors are
drawn into intake manifold. Refer to Group 25, Emis
sion Control System for additional information.
FUEL INJECTORS—3.9L/5.2L/5.9L ENGINES

The fuel injectors are attached to the fuel rail (Fig.
4). 3.9L engines use six injectors. 5.2L and 5.9L
engines use eight injectors.
Fig. 5 Fuel Injectors—8.0L Engine—Typical

The nozzle ends of the injectors are positioned into
openings in the intake manifold just above the intake
valve ports of the cylinder head. The engine wiring
harness connector for each fuel injector is equipped
with an attached numerical tag (INJ 1, INJ 2 etc.).
This is used to identify 'each fuel injector with its
respective cylinder number.
FUEL The injectors are energized individually in a
INJECTOR J9214-30 sequential order by the powertrain control module
(PCM). The PCM will adjust injector pulse width by
Fig. 4 Fuel Injectors—3.9L/5.2L/5.9L Engines- switching the ground path to each individual injector
Typical on and off. Injector pulse width is the period of time
The nozzle ends of the injectors are positioned into that the injector is energized. The PCM will adjust
openings in the intake manifold just above the intake injector pulse width based on various inputs it
valve ports of the cylinder head. The engine wiring receives.
with an attached numerical tag (INJ 1, INJ 2 etc.). FUEL RAIL—3.9L/5.2L/5.9L ENGINES
This is used to identify each fuel injector with its The fuel rail supplies the necessary fuel to each
respective cylinder number. individual fuel injector and is mounted to the intake
The injectors are energized individually in a manifold (Fig. 6). The fuel pressure regulator is no
sequential order by the powertrain control module longer mounted to the fuel rail on any engine. I t is
(PCM). The PCM will adjust injector pulse width by now located on the fuel tank mounted fuel pump
module. Refer to Fuel Filter/Fuel Pressure Regulator

in the Fuel Delivery System section of this group for QUICK-CONNECT FITTINGS
information. The fuel rail is not repairable. Different types of quick-connect fittings are used to
attach various fuel system components. These are: a
single-tab type, a two-tab type or a plastic retainer
ring type. Some are equipped with safety latch clips.
Refer to the Removal/Installation section for more
information.
CAUTION: The interior components (o-rings, spac

ers) of quick-connect fitting are not serviced sepa
rately, but new pull tabs are available for some
types. Do not attempt to repair damaged fittings or
fuel lines/tubes. If repair is necessary, replace the
complete fuel tube assembly.
DIAGNOSIS A H P T E S T I N G
FUEL P U I P PRESSURE TEST—ALL ENGINES

WITH PRESSURE TEST PORT
NOTE: The fuel pressure test port is used on cer

tain engines only. On 3.9L/5.2L/5.9L engines, and
when equipped, the test port will be located on the
Fig. 6 Fuel Raii-3.9iJ5.2IJ5.9L Engines—Typical fuel rail near the throttle position sensor on (Fig. 7).
CAUTION: The left and right sections of the fuel On 8.0L V-10 engines, this test port is located on
rail are connected with a flexible connecting hose. the end of the fuel rail near the engine thermostat
Do not, attempt to separate the rail halves at this housing (Fig. 5). A sealing cap is screwed onto the
connecting hose. Dyetothe design of this connect test port
ing hose, it does not use any clamps. Never attempt
to install a clamping device of any kind to the hose.
NOTE: The vacuum assisted fuel pressure regula
When removing the fuel rail assembly for any rea
tor located at the rear of the fuel rail on 3.9L/5.2L/
son, be careful not to bend or kink the connecting
5.9L engines is no longer used on any engine.
hose.
All fuel systems are equipped with a fuel tank
module mounted, combination fuel filter/fuel pressure
FUEL RAIL—8.0L ENGINE
regulator. The fuel pressure regulator is not con
The fuel rail supplies the necessary fuel to each trolled by engine vacuum.
individual fuel injector and is mounted to the lower With engine at idle speed, system fuel pressure
half of the two-piece intake manifold (Fig. 5). The should be 339 kPa ± 34 kPa (49.2 psi ± 5 psi).
metal, one-piece fuel rail is not repairable.
WARNING: DO NOT ALLOW FUEL TO SPILL ONTO
FUEL TANK FILLER TUBE CAP THE ENGINE INTAKE OR EXHAUST MANIFOLDS.
The loss of any fuel or vapor out of filler neck is P L A C E SHOP T O W E L S UNDER AND AROUND THE
prevented by the use of a pressure-vacuum fuel tank P R E S S U R E PORT TO A B S O R B FUEL.
filler tube cap. Relief valves inside cap will release
only under significant pressure of 6.58 to 8.44 kPa
(1.95 to 2.5 psi). The vacuum release for all gas caps WARNING: WEAR PROPER E Y E PROTECTION
is between .97 and 2.0 kPa (.14 and .29 psi). This cap WHEN TESTING F U E L SYSTEM P R E S S U R E .
must be replaced by a similar unit i f replacement is
necessary. This is in order for the system to remain (1) Remove the protective cap at the fuel rail test
effective. port (Fig. 5) or (Fig. 7). Connect the 0-414 kPa (0-60
psi) fuel pressure gauge (from gauge set 5069) to the
CAUTION: Remove fuel tank filler tube cap before test port pressure fitting on the fuel rail (Fig. 7).
servicing any fuel system component. This is done
to help relieve tank pressure.
DIAGNOSIS a n d TESTING (Continued)

REFER TO THE F U E L SYSTEM PRESSURE
R E L E A S E PROCEDURE.
(1) Release fuel pressure. Refer to the Fuel System

Pressure Release Procedure—-Without Pressure Test
Port.
(2) Disconnect latch clip and fuel line at fuel rail.
Refer to Quick-Connect Fittings for procedures. This
can be found in this section of the group.
(3) Connect adapter tool number 6923 into the fuel
rail (Fig. 8). Be sure adapter tool is fully seated
into fuel rail.
Fig, 7 Fuel Pressure Test Port—3.9U5.2U5.9L

. Engines—Typicai
(2) Start the engine and note pressure gauge read
ing. Fuel pressure should be 339 kPa ± 34 kPa (49.2
psi ± 5 psi) at idle.
(3) I f pressure is at O psi, connect DRB scan tool
and refer to operating instructions in the appropriate
Powertrain Diagnostics Procedures service manual.
(4) I f operating pressure is above 54.2 psi, fuel
pump is OK but fuel pressure regulator is defective.
Fuel, pressure regulator is not serviced separately.
Replace fuel pump module assembly.
Fig. 8 Installing Adapter Tool and Pressure Gauge
FUEL PUMP PRESSURE TEST-ALL ENGINES (4) Install latch clip to fuel rail. I f latch clip can
WITHOUT PRESSURE TEST PORT not be fully seated into fuel rail, check for adapter
tool not fully seated to fuel rail.
NOTE: The fuel pressure test port is used on cer (5) Connect vehicle fuel line into adapter tool 6923
tain engines only. If equipped, the test port will be (Fig. 8). Be sure fuel line is fully seated into adapter
located on the fuel rail near the throttle position tool 6923.
sensor (Fig. 7). If not equipped, refer to the follow (6) Remove protective cap at test port "T" on
:
ing procedure: - adapter tool number 6923.
(7) Connect the 0-414 kPa (0-60 psi) fuel pressure
All fuel systems are equipped with a fuel tank gauge (from gauge set 5069) to the test port "T" (Fig.
module mounted, combination fuel filter/fuel pressure 8).
regulator. The fuel pressure regulator is not con (8) Start engine and note pressure gauge reading.
trolled by engine vacuum. Fuel pressure should be 339 kPa ± 34 kPa (49.2 psi
With engine at idle speed, system fuel pressure ± 5 psi) at idle.
should be 339 kPa ± 34 kPa (49.2 psi ± 5 psi). (9) I f pressure is at 0 psi, connect DRB scan tool
and refer to operating instructions in the appropriate
WARNING: THE F U E L S Y S T E M IS UNDER CON
Powertrain Diagnostics Procedures service manual.
STANT F U E L P R E S S U R E EVEN WITH THE ENGINE
(10) I f operating pressure is above 54.2 psi, fuel
OFF. B E F O R E DISCONNECTING F U E L LINE AT
pump is O K but fuel pressure regulator is defective.
F U E L RAIL, THIS P R E S S U R E MUST B E R E L E A S E D .
Fuel ^ pressure regulator is not serviced separately.
Replace fuel pump module assembly.
(11) After performing pressure test, install fuel
line into fuel rail. Install latch clip into fuel rail.
Refer to Quick-Connect Fittings for procedures. This
can be found in this section of the group.
FUEL GAUGE SENDING UNIT

For fuel gauge diagnosis, refer to Group 8E,
Instrument Panel and Gauges.
FUEL INJECTORS
To perform a complete test of the fuel injectors and
their circuitry, refer to DRB scan tool and appropri
ate Powertrain Diagnostics Procedures manual. To
test the injector only, refer to the following:
Disconnect the fuel injector wire harness connector SPACER J9414-58
from the injector (Fig. 9). Place an ohmmeter across
the injector terminals. Resistance reading should be Fig. 10 Fuel Injector Internal Components—Typical
approximately 14.5 ohms ±1.2 ohms at 20°C (68°F). sensor (Fig. 7 ) . A sealing cap is screwed onto the
Proceed to following Injector Diagnosis chart. When test port.
performing the following tests from the chart,
do not leave electrical current applied to the The fuel system is under constant fuel pressure
injector for longer than five seconds. Damage (even with the engine off).
to injector coil or internal injector seals (Fig.
10) could result. WARNING: BECAUSE THE FUEL SYSTEM IS
UNDER CONSTANT FUEL PRESSURE, THE PRES
SURE MUST BE RELEASED BEFORE SERVICING
ANY FUEL SYSTEM COMPONENT. THIS DOES NOT
APPLY TO THROTTLE BODY REMOVAL.
(1) Disconnect negative battery cable.

(2) Remove the fuel tank filler tube cap to release
fuel tank pressure.
(3) Remove protective cap from pressure test port
on the fuel rail. This is located on top of fuel rail
near the throttle position sensor.
WARNING:' DO NOT ALLOW FUEL TO SPILL ONTO

THE ENGINE INTAKE OR EXHAUST MANIFOLDS.
PLACE SHOP TOWELS UNDER AND AROUND THE
PRESSURE PORT TO ABSORB FUEL WHEN THE
PRESSURE IS RELEASED FROM THE FUEL RAIL.
WARNING: WEAR PROPER EYE PROTECTION

FUEL WHEN RELEASING FUEL SYSTEM PRESSURE.
INJECTOR J9214-30
(4) Obtain the fuel pressure gauge/hose assembly
Fig. 9 Fuel Injector Wiring Connector—Typical from fuel pressure gauge tool set 5069. Remove the
gauge from the hose.
SERVICE PROCEDURES (5) Place one end of hose (gauge end) into an
approved gasoline container.
FUEL SYSTEM PRESSURE RELEASE (6) Place a shop towel under the test port.
PROCEDURE-WITH PRESSURE TEST PORT (7) To release fuel pressure, screw the other end of
hose onto the fuel pressure test port.
NOTE: The fuel pressure test port Is used on cer (8) After fuel pressure has been released, remove
tain engines only. If equipped, the test port will be the hose from the test port.
located on the fuel rail near the throttle position (9) Install protective cap to fuel test port.
BR — — — — — _ FUEL S Y S T E M 14 - 9
D O PRELIMINARY INSPECTION OF START VEHICLE, PULL THE TEST THE INJECTOR RESISTANCE
ELECTRICAL CONNECTORS OFF U S I N G A N OHMMETER ACROSS
DISTRIBUTOR CAP, IGNITION
THE INJECTORS ONE AT A TIME THE INJECTOR TERMINALS W I T H
CABLES SPARK PLUGS, A N D
TO DETERMINE W H I C H CYLINDER THE INJECTOR CONNECTOR
CHECK FOR VACUUM LEAKS,
IS N O T FIRING. REMOVED.
REPLACE THE INJECTOR
PLACE A 12 VOLT TEST L A M P

ACROSS THE INJECTOR
ELECTRICAL CONNECTOR
TERMINALS. OBSERVE THE TEST
LAMP WHILE C R A N K I N G THE
ENGINE.
CHECK POWER FEED A N D

GROUND CIRCUITS BETWEEN
POWERTRAIN CONTROL MODULE
A N D THE INJECTOR CONNECTOR.
- NO-
REFER TO WIRING SCHEMATIC
FOR COLOR CODES A N D PIN
TERMINAL NUMBERS.
CIRCUIT IS OK. CHECK FOR FUEL

DELIVERY AT SUSPECT INJECTOR
BY R E M O V I N G THE INJECTOR
TEST THE VEHICLE WITH THE DRB II F R O M THE RAIL A N D OBSERVING
SCAN TOOL FOR FUEL A N D / O R RESTRICTIONS
I N THE RAIL OR INJECTOR FUEL
INLET.
REPAIR OR REPLACE THE W I R I N G

HARNESS A S NECESSARY.
REPLACE INJECTOR IF VISUALLY

PLUGGED AT INJECTOR FUEL
INLET.
REPLACE FUEL RAIL IF VISUALLY
PLUGGED OR RESTRICTED AT
INJECTOR DELIVERY COUPLING.
W I T H INJECTOR REMOVED F R O M
THE FUEL RAIL, CONNECT A 12V
SOURCE TO O N E TERMINAL O N
THE INJECTOR CONNECTOR A N D
A G R O U N D WIRE TO THE OTHER
TERMINAL. THE INJECTOR
SHOULD " C L I C K " EACH TIME THE
G R O U N D WIRE IS CONNECTED
A N D DISCONNECTED TO THE
TERMINAL.
REPLACE INJECTOR - NO -
J9314-114
INJECTOR DIAGNOSIS—VEHICLE RUNS ROUGH AND/OR HAS A MISS

14 - 11 FUEL SYSTEM mm
SERWiCE P R O C E D U R E S (Continued)
FUEL SYSTEM PRESSURE RELEASE leaks are not present. The component should be
PROCEDURE—WITHOUT PRESSURE TEST PORT replaced immediately i f there is any evidence of deg
Use the following procedure i f the fuel r a i l is radation that could result in failure.
not equipped w i t h a fuel pressure test port. Never attempt to repair a plastic fuel line/tube.
(1) Remove the Fuel Pump relay from the Power Replace as necessary.
Distribution Center (PDC). For location of the relay, Avoid contact of any fuel tubes/hoses with other vehi
refer to the label on the underside of the PDC cover. cle components that could cause abrasions or scuffing.
(2) Start and run engine i t stalls. Be sure that' the plastic fuel lines/tubes are properly
(3) Attempt restarting engine until it will no routed to prevent pinching and to avoid heat sources.
longer run. The lines/tubes/hoses used on fuel injected vehicles
(4) Turn ignition key to OFF position. are of a special construction. This is due to the higher
fuel pressures and the possibility of contaminated fuel
CAUTION: Steps 1, 2, 3 and 4 must be performed to in this system. I f it is necessary to replace these lines/
relieve high pressure fuel f r o m within the fuel rail. tubes/hoses, only those marked EFM/EFI may be used.
Do not attempt to use the following steps t o relieve The hose clamps used to secure rubber hoses on
this pressure as excessive fuel will be forced into a fuel injected vehicles are of a special rolled edge con
cylinder chamber. struction. This construction is used to prevent the
edge of the clamp from cutting into the hose. Only
(5) Unplug connector from any injector. these rolled edge type clamps may be used in this
(6) Attach one end of a jumper' wire with alligator system. A l l other types of clamps may cut into the
clips (18 gauge or smaller) to either injector terminal. hoses and cause high-pressure fuel leaks.
(7) Connect the other end of the jumper wire to Use new original equipment type hose clamps.
the positive side of the battery. Tighten hose clamps to 1 N-m (15 in. lbs.) torque.
(8) Connect one end of a second jumper wire to the
remaining injector terminal. QUICK-CONNECT FITTINGS
Also refer to the Fuel Tubes/Lines/Hoses and
CAUTION: Supplying power to an injector for more Clamps section.
than 4 seconds will permanently damage the injec Different types of quick-connect fittings are used to
tor. Do not leave the injector connected to power attach various fuel system components. These are: a
for more than 4 seconds. single-tab type, a two-tab type, a plastic retainer ring
type or a latch clip type. Certain fittings may require
(9) Momentarily touch the other end of this the use of a special tool for disconnection.
jumper wire to the negative terminal of the battery
for no more than 4 seconds. SINGLE-TAB TYPE
(10) Place a rag or towel below the fuel line at the This type of fitting is equipped with a single pull
quick connect to the rail.. tab (Fig. 11). The tab is removable. After the tab is
(11) Disconnect the quick connect fitting to the removed, the quick-connect fitting can be separated
rail. Refer to Quick-Connect Fittings in this section. from the fuel system component.
(12) Return the fuel pump relay to the PDC.
(13) One or more Diagnostic Trouble Codes (DTCs)
may have been stored in the PCM memory due to
fuel pump relay removal. The DRB scan tool must be
used to erase a DTC. Refer to Group 25, Emission
Control System. See On-Board Diagnostics.
FUEL TUBES/LINES/HOSES AND CLAMPS

Also refer to the section on Quick-Connect Fittings.
WARNING: THE FUEL SYSTEM IS UNDER A CON

STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES, FIT
TINGS OR LINES, THE FUEL SYSTEM PRESSURE / PRESS HERE
MUST BE RELEASED. REFER TO THE FUEL SYSTEM INSERTED TO REMOVE
PRESSURE R E L E A S E PROCEDURE IN THIS GROUP. TUBE END PULL TAB J9414-24
Inspect all hose connections such as clamps, cou Fig. 11 Single-Tab Type Fitting
plings and fittings to make sure they are secure and
FUEL S Y S T E M 14-11
SERW1CE PitOCEPURES {Continued)

CAUTION: The interior components (o-rings, spac FUEL TUBE OR QUICK-CONNECT
ers) of this type of quick-connect fitting are not ser FUEL SYSTEM FITTING
COMPONENT
viced separately, but new pull tabs are available. Do
not attempt to repair damaged fittings or fuel lines/
tubes. If repair is necessary, replace the complete
fuel tube assembly.

STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES, FIT
TINGS OR LINES, THE FUEL SYSTEM PRESSURE
MUST B E RELEASED. REFER TO THE FUEL SYSTEM
PRESSURE R E L E A S E PROCEDURE IN THIS GROUP. FUEL
TUBE
STOP J9414-26
DISCONNECTION/CONNECTION
Fig. 13 Removing Pull Tab
(1) Disconnect negative battery cable from battery
(2) Perform the fuel pressure release procedure. (9) Prior to connecting the quick-connect fitting to
Refer to the Fuel Pressure Release Procedure in this component being serviced, check condition of fitting
section. and component. Clean the parts with a lint-free
(3) Clean the fitting of any foreign material before cloth. Lubricate them with clean engine oil.
disassembly. (10) Insert the quick-connect fitting into the fuel
(4) Press the release tab on the side of fitting to tube or fuel system component until the built-on stop
release pull tab (Fig. 12). on the fuel tube or component rests against back of
fitting.
CAUTION: If this release tab is not pressed prior (11) Obtain a new pull tab. Push the new tab
to releasing the pull tab, the pull tab will be dam down until i t locks into place in the quick-connect fit
aged. ting.
(12) Verify a locked condition by firmly pulling on
(5) While pressing the release tab on the side of the fuel tube and fitting (15-30 lbs.).
fitting, use a screwdriver to pry up the pull tab (Fig. (13) Connect negative cable to battery.
12). (14) Start engine and check for leaks.
SCREWDRIVER
TWO-TAB TYPE FITTING
This type of fitting is equipped with tabs located on
both sides of the fitting (Fig. 14). These tabs are sup
plied for disconnecting the quick-connect fitting from
component being serviced.
QUICK-CONNECT
FITTING
QUICK-CONNECT
FITTING J9414-25
Fig. 12 Disconnecting Single-Tab Type Fitting

(6) Raise the pull tab until it separates from the
quick-connect fitting (Fig. 13). Discard the old pull tab.
(7) Disconnect the quick-connect fitting from the
fuel system component being serviced.
(8) Inspect the quick-connect fitting body and fuel
system component for damage. Replace as necessary. Fig. 14 Typical Two-Tab Type Quick-Connect Fitting
14 - 1 2 FUEL SYSTEM BR
S E R V I C E P R O C E D U R E S {Continued)
CAUTION: The interior components (o-rings spac 5 PLASTIC RETAINER RING TYPE FITTING
ers) of this type of quick-connect fitting are not ser This type of fitting can be identified by the use of a
viced separately, but new plastic retainers are full-round plastic retainer ring (Fig. 15) usually black
available. Do not attempt to repair damaged fittings in color.
or fuel lines/tubes. If repair is necessary, replace
the complete fuel tube assembly.
WARNING: THE F U E L SYSTEM IS UNDER A CON

STANT P R E S S U R E (EVEN WITH THE ENGINE OFF).
B E F O R E SERVICING ANY F U E L SYSTEM H O S E S ,
FITTINGS OR LINES, THE F U E L SYSTEM P R E S
S U R E MUST B E R E L E A S E D . R E F E R TO THE F U E L
PRESSURE RELEASE PROCEDURE IN THIS
GROUP.
INSTALLATION
DISCONNECTION/CONNECTION
(1) Disconnect negative battery cable from the bat
tery.
(2) Perform the fuel pressure release procedure. PUSH- •PUSH
Refer to the Fuel Pressure Release Procedure in this
section.
(3) Clean the fitting of any foreign material before
disassembly.
/
PLASTIC
(4) To disconnect the quick-connect fitting, squeeze RETAINER J9314-100
the plastic retainer tabs (Fig. 14) against the sides of
the quick-connect fitting with your fingers. Tool use Fig. 15 Plastic Retainer Ring Type Fitting
is not required for removal and may damage plastic CAUTION: The interior components (o-rings, spac
retainer. Pull the fitting from the fuel system compo ers, retainers) of this type of quick-connect fitting
nent being serviced. The plastic retainer will remain are not serviced separately. Do not attempt to repair
on the component being serviced after fitting is dis damaged fittings or fuel lines/tubes. If repair is nec
connected. The o-rings and spacer will remain in the essary, replace the complete fuel tube assembly.
quick- connect fitting connector body.
(5) Inspect the quick-connect fitting body and com
ponent for damage. Replace as necessary. WARNING: T H E F U E L S Y S T E M IS UNDER A CON
STANT P R E S S U R E (EVEN WITH THE ENGINE OFF).
CAUTION: When the quick-connect fitting was dis B E F O R E SERVICING ANY F U E L SYSTEM H O S E S ,
connected, the plastic retainer will remain on the FITTINGS OR LINES, THE F U E L SYSTEM P R E S
component being serviced. If this retainer must be S U R E MUST B E R E L E A S E D . R E F E R TO THE F U E L
removed, very carefully release the retainer from S Y S T E M P R E S S U R E R E L E A S E P R O C E D U R E IN
the component with two small screwdrivers. After THIS GROUP.
removal, inspect the retainer for cracks or any dam
age.
ilSCOIIECTIOI/COIIECTIOI
(6) Prior to connecting the quick-connect fitting to (1) Disconnect negative battery cable from the bat
component being serviced, check condition of fitting tery.
and component. Clean the parts with a lint-free (2) Perform the fuel pressure release procedure.
cloth. Lubricate them with clean engine oil. Refer to the Fuel Pressure Release Procedure in this
(7) Insert the quick-connect fitting to the compo section.
nent being serviced and into the plastic retainer. (3) Clean the fitting of any foreign material before
When a connection is made, a click will be heard. disassembly.
• (8) Verify a locked condition by firmly pulling on (4) To release the fuel system component from the
fuel tube and fitting (15-30 lbs.). quick-connect fitting, firmly push the fitting towards
(9) Connect negative cable to battery. the component being serviced while firmly pushing
(10) Start engine and check for leaks. the plastic retainer ring into the fitting (Fig. 15).
With the plastic ring depressed, pull the fitting from
en FUEL SYSTEM 4 • 13
the component. The plastic retainer ring must be
pressed squarely into the fitting body. If this
retainer is cocked during removal, it may be
difficult to disconnect fitting. Use an open-end
wrench on the shoulder of the plastic retainer
ring to aid in disconnection.
(5) After disconnection, the plastic retainer ring
will remain with the quick-connect fitting connector
body.
(6) Inspect fitting connector body, plastic retainer
ring and fuel system component for damage. Replace
as necessary.
(7) Prior to connecting the quick-connect fitting to
component being serviced, check condition of fitting
and component. Clean the parts with a lint-free
cloth. Lubricate them with clean engine oil.
(8) Insert the quick-connect fitting into the compo Fig. 16 Latch dip Location—Typical
nent being serviced until a click is felt.
(9) Verify a locked condition by firmly pulling on
fuel tube and fitting (15-30 lbs.).
(10) Connect negative battery cable to battery.
(11) Start engine and check for leaks.
FUEL LINE AT FUEL RAIL—3.9L/5.2L/5.9L

ENGINES
Use the following procedure if the fuel rail is
equipped with a fuel pressure test port.
A latch clip is used to secure the fuel line to the
fuel rail on certain engines (Fig. 16). A special tool
will be necessary to separate the fuel line from the
fuel rail after the latch clip is removed.
DISCONNECTION/CONNECTION AT FUEL RAIL J9514-5
(1) Disconnect the negative battery cable from bat

tery. Fig. 17 Latch Clip Removal—Typical
(2) Perform the fuel pressure release procedure.
section.
disassembly.
(4) Pry up on the latch clip with a screwdriver
(Fig. 17).
(5) Slide the latch clip toward the fuel rail while
lifting with the screwdriver.
(6) Insert special fuel line removal tool (Snap-On
number F I H 9055-1 or equivalent) into the fuel line
(Fig. 18). Use this tool to release the locking fingers
in the end of the line.
(7) With the special tool still inserted, pull the
fuel line from the fuel rail. j ^ — — - F U E L RAIL J9514-6
(8) After disconnection, the locking fingers will
remain within the quick-connect fitting at the end of Fig. 18 Fuel Line Disconnection—Typical
the fuel line.
with a lint-free cloth. Lubricate them with clean
(9) Inspect fuel line fitting, locking fingers and
engine oil.
fuel rail fitting for damage. Replace as necessary.
(11) Insert the fuel line onto the fuel rail until a
(10) Prior to connecting the fuel line to the fuel
click is felt.
rail, check condition of both fittings. Clean the parts
14 - 1 4 FUEL SYSTEM BR
(12) Verify a locked condition by firmly pulling on fuel rail i f properly installed (Fig. 20). I f the latch
fuel line and fitting (15-30 lbs.). clip will not fit, this indicates the fuel line is
(13) Install latch clip (snaps into position). I f the not properly installed to the fuel rail. Recheck
latch clip w i l l not fit, this indicates the fuel line the fuel line connection.
is not properly installed to the fuel rail.
Recheck the fuel line connection.
(14) Connect negative battery cable to battery
FUEL LINE AT FUEL RAIL—3.9L/5.2L/5.9L

ENGINES
Use the following procedure if the fuel rail is
not equipped with a fuel pressure test port.
A special latch clip is used to secure the fuel line to
the fuel rail on this particular engine (Fig. 19).
DISCONNECTION/CONNECTION AT FUEL RAIL

tery.
8031e888
section. Fig. 20 Latch Clip Installation
(3) Clean the fitting of any foreign material before (11) Verify a locked condition by firmly pulling on
disassembly. fuel line and fitting (15-30 lbs.).
(4) Pry up on the latch clip with two small screw (12) Connect negative battery cable to battery.
drivers (Fig. 19). (13) Start engine and check for leaks.
FUEL LINE AT FUEL BAIL—8ML V-10 ENGINE

A special tool will be necessary to separate the fuel
line at the rear of fuel rail. The tool is designed to
release the locking fingers within the fittings. Use
OTC® fuel line release tool number 7660 or equiva
lent.
tery.
section.
(3) Remove the air cleaner housing.
LATCH F U E L LINE
disassembly.
8031e889
(5) Install special fuel line tool to fuel line to
unlock fuel line fingers.
Fig. 19 Latch Clip Removal
(6) Pull the fuel line from the fuel rail.
(5) Pull the fuel line from the fuel rail. (7) After disconnection, the locking fingers will
(6) After disconnection, the locking fingers will remain within the quick-connect fitting in the fuel
remain within the quick-connect fitting in the fuel rail.
rail. (8) Inspect fuel line fitting, locking fingers and
(7) Inspect fuel line fitting, locking fingers and fuel rail fitting for damage. Replace as necessary.
fuel rail fitting for damage. Replace as necessary. (9) Prior to connecting the fuel line to the fuel
(8) Prior to connecting the fuel line to the fuel rail, check condition of both fittings. Clean the parts
rail, check condition of both fittings. Clean the parts with a lint-free cloth. Lubricate them with clean
with a lint-free cloth. Lubricate them with clean engine oil.
engine oil. (10) Insert the fuel line into the fuel rail.
(9) Insert the fuel line into the fuel rail. (11) Verify a locked condition by firmly pulling on
(10) Install latch clip with fingers down (snaps fuel line and fitting (15-30 lbs.).
into position). The fingers should protrude below the (12) Connect negative battery cable to battery.
BR FUEL SYSTEM 14 - 1 5
(13) Start engine and check for leaks. remove locknut (Fig. 24). The fuel pump module will
spring up when the locknut is removed.
(4) Remove module from fuel tank.
PLASTIC FUEL FILTER/ FUEL
TOP O F
FUEL FILTER/FUEL PRESSURE REGULATOR LOCKNUT FUEL PRESSURE SUPPLY
FUEL T A N K
REGULATOR CONNECTION
If the filter or regulator needs service, the Fuel
Pump Module assembly must be replaced. Refer to
Fuel Pump Module for procedures.
PRESSURE RELIEF/
FUEL PUMP RELAY ROLLOVER VALVE
The fuel pump and automatic shutdown (ASD)
relays are located in the Power Distribution Center
(PDC). The PDC Is located i n the engine compart
ment (Fig. 21). Refer to label on PDC cover for relay
location. Check the terminals in the PDC relay con , PUMP/GAUGE
AUXILIARY - RUBBER G R O M M E T ELEC. C O N N E C T I O N
nector for corrosion or damage before installation. F U E L SUPPLY
FITTING FRONTOF"
POWER (SOME ENGINES) TANK J9414-32
DISTRIBUTION
CENTER
(PDC) Fig. 22 Top View of Fuel Pump Module
FLOAT S E N D I N G UNIT TABS
ELECTRIC
FUEL PUMP
J9414-10

MOUNTING IN-TANK
FUEL P U i P MODULE SCREWS FUEL FILTER J9414-33
mmowAL Fig. 23 Fuel Pump Module Components—Typical
WARNING: THE FUEL S Y S T E M IS UNDER A CON

STANT P R E S S U R E (EVEN WITH THE ENGINE OFF). SPECIAL
B E F O R E SERVICING T H E F U E L PUMP MODULE, TOOL
THE FUEL SYSTEM PRESSURE MUST B E 6856
RELEASED.
CAUTION: Whenever the fuel pump module is ser

viced, the locknut and gasket must be replaced.
(1) Drain the fuel tank. Refer to Draining Fuel

Tank in the Fuel Tank section of this group.
(2) Remove fuel tank. Refer to the Fuel Tank sec
tion of this group.
(3) The plastic fuel pump module locknut is
threaded onto the fuel tank (Fig. 22). Install Special
Tool 6856 to the fuel pump module locknut and Fig. 24 Locknut Removal/Installation—Typical

INSTALLATION
CAUTION; Whenever the fuel pump module is ser

viced, the locknut and gasket must be replaced.
(1) Using a new gasket, position fuel pump module

into opening in fuel tank.
( 2 ) Position new locknut over top of fuel pump
module.
(3) Install Special Tool 6856 to locknut.
(4) Tighten locknut to 54 N-m (40 ft. lbs.) torque.
(5) Install fuel tank. Refer to Fuel Tank Installa
tion in this section.
FUEL PUMP INLET STRAINER

The fuel pump inlet strainer (in-tank fuel filter) is
not serviced separately. I f i t needs service, the fuel
pump module assembly must be replaced. Refer to
Fuel Pump Module Removal/Installation.
FUEL LEVEL SENSOR

The fuel level sensor (fuel gauge sending unit) is
not serviced separately. I f i t needs service, the fuel Fig. 25 Fuel Rail Assembly—Typical
pump module assembly must be replaced. Refer to
Fuel Pump Module Removal/Installation. AIR CONDITIONING
/COMPRESSOR SUPPORT BRACKET
FUEL INJECTOR RAIL—3.9L/5.2L/5.9L ENGINES

STANT P R E S S U R E (EVEN WITH THE ENGINE
TURNED OFF). B E F O R E SERVICING THE F U E L
RAIL ASSEMBLY, THE F U E L SYSTEM P R E S S U R E
MUST B E R E L E A S E D .
To release fuel pressure, refer to the Fuel System

Pressure Release Procedure found in this group.
CAUTION: The left and right fuel rails are replaced

as an assembly. Do not attempt to separate the rail MOUNTING BOLTS J9214-49
halves at the connecting hose (Fig. 25). Due to the
design of this connecting hose, it does use any Fig. 26 A/C Compressor Support Bracket—Typical
clamps. Never attempt to install a clamping device harness is numerically tagged (INJ 1, I N J 2, etc.) for
of any kind to the hose. When removing the fuel rail injector position identification.
assembly for any reason, be careful not to bend or (7) 3.9L (V-6) engine only: Disconnect electrical
kink the connecting hose. connector at intake manifold air temperature sensor.
Do not remove sensor.
REMOVAL (8) Remove duty cycle EVAP canister purge sole
(1) Remove negative battery cable at battery. noid/bracket assembly (Fig. 28) from intake manifold.
(2) Remove air cleaner. (9) Disconnect fuel tube (line) at side of fuel rail.
(3) Perform the fuel pressure release procedure. Refer to Quick-Connect Fittings for procedures,
(4) Remove throttle body from intake manifold. (10) Remove the remaining fuel rail mounting
Refer to Throttle Body removal in this group. bolts.
(5) I f equipped with air conditioning, remove the (11) Gently rock and pull the left fuel rail until
A-shaped A/C compressor-to-intake manifold support the fuel injectors just start to clear the intake mani
bracket (three bolts) (Fig. 26). fold. Gently rock and pull the r i g h t fuel rail until
(6) Disconnect electrical connectors at all fuel the fuel injectors just start to clear the intake mani-
injectors (Fig. 27). The factory fuel injection wiring
B R — _ — • FUEL SYSTEM 14 -17
INJECTOR J9214-24
Fig. 29 Fuel Injector Mounting—Typical
PLIERS
FUEL
INJECTOR J9214-30
Fig. 27 Fuel injector Connectors—Typical
J9414-156
Fig. 30 Injector Retaining Clips—Typical Injector

(2) Install injector(s) and injector clip(s) to fuel
rail.
(3) Position the fuel rail/fuel injector assembly to
the injector openings on the intake manifold.
( 4 ) Guide each injector into the intake manifold.
Be careful not to tear the injector o-ring.
Fig. 28 EVAP Canister Purge Solenoid—Typical ( 5 ) Push the r i g h t fuel rail down until fuel injec
fold. Repeat this procedure (left/right) until all fuel tors have bottomed on injector shoulder. Push the
injectors have cleared the intake manifold. left fuel rail down until fuel injectors have bottomed
(12) Remove fuel rail (with injectors attached) on injector shoulder.
from engine. (6) Install fuel rail mounting bolts.
(13) Remove the clip(s) retaining the injector(s) to (7) Install EVAP canister purge solenoid to intake
fuel rail (Fig. 29) or (Fig. 30). manifold.
(8) Connect electrical connector to intake manifold
INSTALLATION air temperature sensor.
(1) Apply a small amount of engine oil to each fuel ( 9 ) Connect wiring to all fuel injectors. The injec
injector o-ring. This will help i n fuel rail installation. tor wiring harness is numerically tagged.
(10) Install the A/C support bracket (if equipped). (6) Remove upper half of intake manifold. Refer to
(11) Install throttle body to Intake manifold. Refer Group 11, Exhaust System and Intake Manifold for
to Throttle Body installation i n this section of the procedures.
group. (7) Disconnect electrical connectors at all fuel
(12) Install fuel tube (line) at side of fuel rail. injectors. The factory fuel injection wiring harness is
Refer to Quick-Connect Fittings for procedures. numerically tagged (INJ 1, I N J 2, etc.) for injector
(13) Install air cleaner. position identification.
(14) Connect battery cable to battery. (8) Disconnect main fuel line at fuel rail. On the
(15) Start engine and check for leaks. 8.0L V-10 engine, the fuel line-to-fuel rail connection
is made at the rear of the engine. A special tool will
FUEL INJECTOR RAIL—8.0L ¥ 4 1 ENOINE be necessary for disconnection. Refer to Quick-Con
nect Fittings for procedures.
REMOVAL (9) Remove the six fuel rail mounting bolts from
the lower half of intake manifold (Fig. 32).
STANT P R E S S U R E EVEN WITH T H E ENGINE OFF. ELECTRICAL MOUNTING
B E F O R E SERVICING THE F U E L RAIL, THE F U E L CONNECTOR BOLTS (6)
S Y S T E M P R E S S U R E MUST B E R E L E A S E D .
(1) Remove negative battery cable at battery.

(2) Remove air cleaner housing and tube.
Refer to the Fuel Delivery System section of this
group.
(4) Disconnect throttle body linkage and remove
throttle body from intake manifold. Refer to Throttle
Body removal in this group.
(5) Remove ignition coil pack and bracket assem
bly (Fig. 31) at intake manifold and right engine
valve cover (four bolts).
COIL PACKS
AND BRACKET
Fig. 32 Fuel Rail Mounting Bolts—8.0L V-10

Engine—Typical
(10) Gently rock and pull the left fuel rail until
the fuel injectors just start to clear the intake mani
fold. Gently rock and pull the r i g h t fuel rail until
MOUNTING
BOLTS (4) the fuel injectors just start to clear the intake mani
fold. Repeat this procedure (left/right) until all fuel
injectors have cleared the intake manifold.
(11) Remove fuel rail (with injectors attached)
from engine.
(12) Remove the clip(s) retaining the injector(s) to
fuel rail (Fig. 29) or (Fig. 30).
INSTALLATION
FRONT OF ENGINE J9414-55
(1) Apply a small amount of engine oil to each fuel
injector o-ring. This will help in fuel rail installation.
Fig. 31 ignition Coif Pack and Mounting
(2) Install injector(s) and injector clip(s) to fuel
Bracket—8.0L V-10 Engine
rail.
FUEL SYSTEM 14 - 1 9
NOTE: The fuel injector electrical connectors on (2) Install injector(s) and injector clip(s) to fuel
all 10 injectors should be facing to the right (pas rail.
senger) side of the vehicle (Fig. 32). (3) Install fuel rail assembly. Refer to Fuel Injector
Rail installation.
(3) Position the fuel rail/fuel Injector assembly to (4) Install air cleaner.
the injector openings on the intake manifold. (5) Start engine and check for leaks.
(4) Guide each injector into the intake manifold.
Be careful not to tear the injector o-ring. FUEL TANK—ALL ENGINES
(5) Push the r i g h t fuel rail down until fuel injec
tors have bottomed on injector shoulder. Push the DRAINING FUEL TANK
left fuel rail down until fuel injectors have bottomed (1) Remove fuel tank filler tube cap to release fuel
on injector shoulder. tank pressure.
(6) Install the six fuel rail mounting bolts into the (2) Perform Fuel System Pressure Release proce
lower half of intake manifold. Tighten bolts to 15 dure as described in this group.
N-m (136 in. lbs.) torque. (3) Raise vehicle on hoist.
(7) Connect wiring to all fuel injectors. The injec (4) While working over the left rear tire/wheel, dis
tor wiring harness is numerically tagged. connect the rubber fuel fill hose and clamp at fuel
(8) Install upper half of intake manifold. Refer to tank (Fig. 33). Position fuel siphoning/drain hose into
Group 11, Exhaust System and Intake Manifold for this opening at tank.
procedures.
FUEL FUEL
(9) Connect main fuel line at fuel rail. Refer to PUMP TANK
VENT TUBE
Quick-Connect Fittings for procedures. MODULE,
AND HOSE
(10) Install ignition coil pack and bracket assem
bly at intake manifold and right engine valve cover
(four bolts).
(11) Install throttle body to intake manifold. Refer
to Throttle Body removal in this group.
(12) Install throttle body linkage to throttle body.
(13) Install air cleaner tube and housing.
(14) Install negative battery cable at battery.
FUEL INJECTOR(S)—ALL GAS ENGINES

STANT P R E S S U R E EVEN WITH THE ENGINE C L A M P S (4)
FUEL T A N K
TURNED OFF. B E F O R E SERVICING THE F U E L FILLER T U B E
INJECTOR(S), THE F U E L SYSTEM PRESSURE CAP F U E L FILL
T U B E AND HOSE
MUST B E R E L E A S E D .
DRIVER'S mm
To release fuel pressure, refer to the Fuel System OF VEHICLE
J9414-36
Pressure Release Procedure.

To remove one or more fuel injectors, the fuel rail Fig. 33 Fuel Tank Fill and Vent Hoses
assembly must be removed from engine. (5) Drain fuel into an approved portable holding
tank or a properly labeled gasoline safety container.
REMOVAL
(1) Remove air cleaner assembly. TANK REMOVAL
(2) Remove fuel injector rail assembly. Refer to (1) Disconnect negative battery cable at battery.
Fuel Injector Rail removal in this section. (2) Remove fuel tank filler tube cap.
(3) Remove the clip(s) retaining the injector(s) to
fuel rail (Fig. 29) or (Fig. 30). WARNING: THE F U E L SYSTEM IS UNDER A CON
(4) Remove injector(s) from fuel rail. STANT P R E S S U R E EVEN WITH THE ENGINE OFF.
B E F O R E SERVICING THE F U E L TANK, F U E L S Y S
INSTALLATION TEM P R E S S U R E MUST B E R E L E A S E D . R E F E R TO
(1) Apply a small amount of engine oil to each fuel THE F U E L SYSTEM P R E S S U R E R E L E A S E PROCE
injector o-ring. This will help in fuel rail installation. DURE B E F O R E SERVICING THE FUEL TANK.
FUEL U N E
ELECTRICAL
(a) While working over the left rear tire/wheel,
( T O F U E L RAIL)
DRIVER'S SIDE CONNECTOR disconnect the electrical connector from the fuel
pump module (Fig. 34).
(b) Disconnect the EVAP hose at the pressure
EVAP relief/rollover valve (Fig. 34).
HOSE (c) Disconnect the fuel supply line at the fuel fil
ter/fuel pressure regulator (Fig. 34). Refer to
Quick-Connect Fittings for procedures.
(6) Diesel Powered Engines:
(a) While working over the left rear tire/wheel,
disconnect the electrical connector from the fuel
tank module (Fig. 35).
(b) Disconnect the fuel supply and fuel return
lines at the fuel tank module (Fig. 35). Refer to
Quick-Connect Fittings for procedures.
(7) Place a transmission jack under the center of
FUEL FILTER/
the fuel tank. Apply a slight amount of pressure to
FUEL PRESSURE fuel tank with transmission jack.
REGULATOR
WARNING: WRAP SHOP TOWELS AROUND HOSES

FUEL T A N K
(GAS POWERED) J9414-37 TO CATCH ANY GASOLINE SPILLAGE.
Fig. 34 Fuel Tank Connections—Gas Powered (8) Remove the fuel tank mounting strap nuts at
Engines the mounting straps (Fig. 36). I f equipped, remove
the fuel tank heat shield bolts (Fig. 36).
FUEL RETURN
A N D SUPPLY U N E S
DRIVER'S SIDE
DRIVER'S SIDE OF VEHICLE HEAT
OF VEHICLE SHIELD
FUEL
TANK STRAP MOUNTING
(DIESEL)
J9414-38 NUTS J9414-39
Fig. 35 Fuel Tank Connections—Diesel Powered Fig. 36 Fuel Tank Mounting—Typical

Engines (9) Lower fuel tank for removal.
(3) Drain fuel tank. Refer to the previous Draining
Fuel Tank section. TANK INSTALLATION
(4) Disconnect both the fuel fill and fuel vent rub (1) Place fuel tank on top of transmission jack.
ber hoses at the fuel tank (Fig. 33). ( 2 ) Raise tank into position in the frame cross-
(5) Gas Powered Engines: members.
(3) Connect the two mounting straps and mount
ing strap nuts.

(4) Remove transmission jack. Tighten strap nuts CABLE FRONT Of
to 41 N-m (30 ft. lbs.) torque. Do not over tighten STOP W-v VEHICLE
retaining strap nuts.
(5) Gas Powered Engines:
(a) Connect the electrical connector to the fuel
pump module (Fig. 34).
(b) Connect the EVAP hose at the pressure
relief/rollover valve (Fig. 34).
(c) Connect the fuel supply line at the fuel filter/
fuel pressure regulator (Fig. 34). Refer to Quick-
Connect Fittings for procedures.
Diesel Powered Engines:
(d) Connect the electrical connector to the fuel
tank module (Fig. 35).
(e) Connect the fuel supply and fuel return lines
at the fuel tank module (Fig. 35). Refer to Fuel
Tubes/Lines/Hoses and Clamps in this group for
additional information about fuel line removal and
installation. Also refer to Quick-Connect Fittings In
this group.
(6) Install the rubber fill and vent lines to tank.
Tighten hose clamps to 2.3 N-m (20 In. lbs.) torque.
(7) Refill fuel tank and inspect a l l hoses' and lines Fig. 37 Cable Removal/Installation
for leaks.
(8) Connect negative battery cable to battery. PEDAL MOUNTING
BRACKET
ACCELERATOR PEOAL
REMOVAL
CAUTION: Be careful not to damage or kink the

cable core wire (within the cable sheathing) while
servicing accelerator pedal or cables.
(1) From inside the vehicle, hold up the accelerator

pedal. Remove the plastic cable retainer and throttle
cable core wire from upper end of pedal arm (Fig.
37). The plastic cable retainer snaps, into pedal the
arm.
(2) Insert a small screwdriver into the square
holes located on the pivots/bushings (Fig. 38). Twist
the screwdriver to disengage the pivot locks from the
pivot pin. Pivots will be damaged when removing.
Discard old pivots. -
(3) Remove pedal/bracket assembly from vehicle. J9414-40
INSTALLATION
Fig. 38 Accelerator Pedal—Removal or Installation
(1) Position pedal/bracket assembly over the pivot
pin (Fig. 38). pedal arm (the plastic retainer is snapped Into the
(2) Install two new pivots/bushings. Using large pedal arm). When Installing the plastic retainer to
pliers, press both of the bushings together until they the accelerator pedal arm, note the Index tab on the
bottom on the sides of the pedal/bracket assembly. pedal arm (Fig. 37). Align the index slot on the plas
Bushing retaining ears will snap Into position when tic cable retainer to this index tab.
properly installed.
pedal. Install the throttle cable core wire and plastic
cable retainer into and through the upper end of the
THROTTLE CABLE PRESS TAB FOR
CABLE REMOVAL
CAUTION; Be careful not to damage or kink the
cable core wire (within the cable sheathing) while
servicing accelerator pedal or cables.
REMOVAL
37). The plastic cable retainer snaps into pedal the
arm,
(2) Remove the cable core wire at the pedal arm.
(3) Remove the air cleaner housing.
(4) From Inside the vehicle, pinch both sides of the
plastic cable housing retainer tabs at the dash panel
(Fig. 37).
(5) Remove cable housing from dash panel and
pull the cable Into the engine compartment.
MOUNTING
(6) 3.9L/5.2L/5.9L Engines: Disconnect the cable
BRACKET J9414-44
from the routing/holddown clip at the radiator fan
shroud.
Fig. 40 Throttle Cable at Throttle Body—8.0L V-10
(7) 8.0L V-10 Engine: Remove the throttle cable
Engine
socket at throttle lever ball. (Fig. 40) (snaps off).
(8) 3.9L/5.2L/5.9L Engines: Slip the cable end
rearward from pin on throttle body (Fig. 39).
Fig. 41 Cable Release Tab—3.9U5.2U5.9L

Engines—Typical
cable housing straight up from bracket while press
ing on release tab. Remove throttle cable from vehi
cle.
INSTALLATION
(1) 3.9L/5.2L/5.9L Engines:
Fig. 39 Throttle Cable at Throttle Body—3.9U5.2U (a) Rotate and hold the throttle cam i n the full
5.9L Engines—Typical wide open position. Snap the cable end onto lever
pin (Fig. 39).
(9) Remove cable housing at throttle body mount (b) Connect cable to throttle body mounting
ing bracket by pressing on release tab with a small bracket (push down and lock).
screwdriver (Fig. 41) or (Fig. 40). To prevent cable (c) Connect cable to fan shroud routing clip.
housing breakage, press on the tab only enough (2) 8 . 0 L V-10 Engine:
to release the cable from the bracket. Lift the

(a) Connect cable end socket to throttle body FUEL TANK CAPACITY
lever ball (snaps on) (Fig. 40).
(b) Connect cable to throttle body mounting Models Liters U.S. Gallons
bracket (push down and lock). 118" Wheelbase 98 26
(3) Install the remaining cable housing end into All Other Models 132 35
and through the dash panel opening (snaps into posi
tion). The two plastic pinch tabs (Fig. 37) should lock Nominal refill capacities are shown. A variation may
the cable to dash panel. be observed from vehicle to vehicle due to
(4) From inside the vehicle, hold up the accelera manufacturing tolerance and refill procedure.
tor pedal. Install the throttle cable core wire and
plastic cable retainer into and through the upper end FUEL SYSTEM P R E S S U R E
of the pedal arm (the plastic retainer is snapped into All Engines: 339 kPa ± 34 kPa (49.2 psi ± 5 psi)
the pedal arm). When installing the plastic retainer
to the accelerator pedal arm, note the index tab on TORQUE SPECIFICATIONS
the pedal arm (Fig. 37). Align the index slot on the
plastic cable retainer to this Index tab. DESCRIPTION TORQUE
Fuel Pump Module Locknut 54 N-m (40 ft. lbs.)
Fuel Rail Mounting Bolts—
SPECIFICATIONS 3.9L/5.2L/5.9L Engines 23 N-m (200 in. lbs.)
Fuel Rail Mounting Bolts—
VECI LABEL SPECIFICATIONS 8.0L Engine .15 N-m (136 in. lbs.)
If anything differs between the specifications found Fuel Tank Mounting Nuts . . . . . .41 N-m (30 ft. lbs.)
on the Vehicle Emission Control Information (VECI) Fuel Hose Clamps 1 N-m (15 in. lbs.)
tions on VECI label. The VECI label is located in the
engine compartment.
FUEL INJECTION SYSTEM-GASOLINE ENGINES
INDEX
page page
GENERAL INFORMATION IDLE AIR CONTROL (IAC) MOTOR—8.0L

INTRODUCTION 25 ENGINE—PCM OUTPUT 39
MODES O F OPERATION 26 IGNITION CIRCUIT S E N S E — P C M INPUT 34
DESCRIPTION AND OPERATION IGNITION COILS—8.0L ENGINE—PCM
AIR CONDITIONING (A/C) CLUTCH RELAY— OUTPUTS 40
PCM OUTPUT 37 IGNITION COIL—3.9L/5.2L/5.9L ENGINES—
AIR CONDITIONING (A/C) CONTROLS—PCM PCM OUTPUT 40
INPUT 29 INTAKE MANIFOLD AIR TEMPERATURE
AUTO SHUTDOWN (ASD) RELAY—PCM SENSOR—3.9L/5.2L/5.9L ENGINES—PCM
OUTPUT 38 INPUT 34
AUTOMATIC SHUTDOWN (ASD) RELAY—PCM INTAKE MANIFOLD AIR TEMPERATURE
INPUT 29 SENSOR—8.0L ENGINE—PCM INPUT 34
BATTERY TEMPERATURE SENSOR—PCM MALFUNCTION INDICATOR (CHECK ENGINE)
INPUT 30 LAMP—PCM OUTPUT 41
BATTERY VOLTAGE—PCM INPUT 30 MANIFOLD ABSOLUTE P R E S S U R E (MAP)
BRAKE SWITCH—PCM INPUT 30 SENSOR—3.9L/5.2L/5.9L ENGINES—PCM
CAMSHAFT POSITION SENSOR—3.9L/5.2L/ INPUT 35
5.9L ENGINES—PCM INPUT 30 MANIFOLD ABSOLUTE P R E S S U R E (MAP)
CAMSHAFT POSITION SENSOR—8.0L SENSOR—8.0L ENGINE—PCM INPUT 35
ENGINE—PCM INPUT 30 OUTPUT SHAFT S P E E D S E N S O R — P C M
CRANKSHAFT POSITION SENSOR—3.9L/5.2L/ INPUT 35
5.9L ENGINES—PCM INPUT 30 OVERDRIVE LAMP—PCM OUTPUT 41
CRANKSHAFT POSITION SENSOR—8.0L OVERDRIVE/OVERRIDE SWITCH-PCM INPUT . 36
ENGINE—PCM INPUT 31 POWER GROUND 37
DATA LINK CONNECTOR—PCM INPUT AND POWERTRAIN CONTROL MODULE (PCM) 28
OUTPUT 38 S E R V I C E REMINDER INDICATOR (SRI)
DUTY C Y C L E EVAP PURGE SOLENOID LAMP—PCM OUTPUT 41
VALVE-PCM OUTPUT 38 S P E E D CONTROL SOLENOIDS—PCM
ENGINE COOLANT TEMPERATURE S E N S O R — OUTPUT 41
3.9L/5.2L/5.9L ENGINES—PCM INPUT 31 S P E E D CONTROL SWITCH—PCM INPUT 36
ENGINE COOLANT TEMPERATURE S E N S O R — SYSTEM DIAGNOSIS 28
8.0L ENGINE—PCM INPUT 31 TACHOMETER—PCM OUTPUT 41
FIVE VOLT S E N S O R SUPPLY—PRIMARY 30 THREE-FOUR SHIFT SOLENOID—PCM
FIVE VOLT SENSOR SUPPLY—SECONDARY . . 30 OUTPUT 42
FUEL INJECTORS—3.9L/5.2L/5.9L ENGINES— THROTTLE BODY—3.9L/5.2L/5.9L ENGINES . . . 42
PCM OUTPUT 38 THROTTLE BODY—8.0L ENGINE 43
FUEL INJECTORS—8.0L ENGINE—PCM THROTTLE POSITION S E N S O R (TPS)—3.9U
OUTPUT 39 5.2L/5.9L ENGINES—PCM INPUT 36
FUEL L E V E L SENSOR—PCM INPUT 30 THROTTLE POSITION S E N S O R (TPS)—8.0L
FUEL PUMP RELAY-PCM OUTPUT 39 ENGINE—PCM INPUT 36
GENERATOR FIELD—PCM OUTPUT 39 TORQUE CONVERTOR CLUTCH (TCC)
GENERATOR LAMP—PCM OUTPUT 39 SOLENOID—PCM OUTPUT 42
HEATED OXYGEN SENSOR (02S)—3.9L/5.2L/ TRANSMISSION GOVERNOR P R E S S U R E
5.9L LDC ENGINES—PCM INPUT 32 SENSOR—PCM INPUT 36
HEATED OXYGEN SENSOR (02S)—8.0L MDC TRANSMISSION PARK/NEUTRAL S W I T C H -
ENGINES—PCM INPUT 33 PCM INPUT 36
HEATED OXYGEN SENSOR (02S)—HDC TRANSMISSION P R E S S U R E SENSOR—PCM
ENGINES—PCM INPUT 33 INPUT 36
IDLE AIR CONTROL (IAC) MOTOR—3.9L/5.2L/ TRANSMISSION RELAY—PCM OUTPUT 42
5.9L ENGINES—PCM OUTPUT 39
BR — — FUEL SYSTEM 14 - 25
TRANSMISSION TEMPERATURE S E N S O R — AIR CLEANER HOUSING/AIR CLEANER

PCM INPUT 36 ELEMENT (FILTER)—8.0L V-10 ENGINE 64
VARIABLE F O R C E SOLENOID—PCM OUTPUT . 42 AUTOMATIC SHUTDOWN (ASD) RELAY 57
VEHICLE S P E E D AND DISTANCE S E N S O R — CAMSHAFT POSITION SENSOR 62
PCM INPUT 37 CRANKSHAFT POSITION SENSOR 62
DIAGNOSIS AND TESTING DUTY C Y C L E EVAP CANISTER P U R G E
ASD AND FUEL PUMP RELAYS 48 SOLENOID—3.9L/5.2L/5.9L ENGINES 61
CAMSHAFT AND CRANKSHAFT POSITION DUTY C Y C L E EVAP CANISTER P U R G E
SENSORS 52 SOLENOID—8.0L ENGINE 61
ENGINE COOLANT TEMPERATURE S E N S O R — ENGINE COOLANT TEMPERATURE S E N S O R —
3.9L/5.2L/5.9L ENGINES 53 3.9L/5.2L/5.9L ENGINES 65
ENGINE COOLANT TEMPERATURE S E N S O R — ENGINE COOLANT TEMPERATURE S E N S O R —
8.0L ENGINE 53 8.0L ENGINE 65
HEATED OXYGEN (02S) SENSORS—3.9L/5.2L/ FUEL PUMP RELAY 57
5.9L LCD ENGINES 51 IDLE AIR CONTROL (IAC) MOTOR—3.9L/5.2L/
HEATED OXYGEN (02S) SENSORS—5.9L HDC 5.9L ENGINES 59
ENGINE 52 IDLE AIR CONTROL (IAC) MOTOR—8.0L
HEATED OXYGEN (02S) SENSORS—8.0L ENGINE 60
HDC/MDC ENGINES 52 INTAKE MANIFOLD AIR TEMPERATURE
IDLE AIR CONTROL (IAC) MOTOR—3.9L/5.2L/ SENSOR—3.9L/5.2L/5.9L ENGINES 66
5.9L ENGINES 54 INTAKE MANIFOLD AIR TEMPERATURE
IDLE AIR CONTROL (IAC) MOTOR—8.0L SENSOR—8.0L ENGINE 66
ENGINE 54 MANIFOLD ABSOLUTE P R E S S U R E (MAP)
INTAKE MANIFOLD AIR TEMPERATURE SENSOR—3.9L/5.2L/5.9L ENGINES 60
SENSOR—3.9L/5.2L/5.9L ENGINES 54 MANIFOLD ABSOLUTE P R E S S U R E (MAP)
INTAKE MANIFOLD AIR TEMPERATURE SENSOR—8.0L ENGINE 60
SENSOR—8.0L ENGINE 54 OXYGEN SENSORS—3.9L/5.2L/5.9L LDC/HDC
MANIFOLD ABSOLUTE P R E S S U R E (MAP) ENGINES 62
SENSOR TEST—3.9L/5.2L/5.9L ENGINES . . . 50 OXYGEN SENSORS—8.0L ENGINES 63
MANIFOLD ABSOLUTE P R E S S U R E (MAP) POWERTRAIN CONTROL MODULE (PCM) 62
SENSOR TEST—8.0L ENGINE 51 THROTTLE BODY—3.9L/5.2L/5.9L ENGINES . . . 57
THROTTLE BODY MINIMUM AIR FLOW C H E C K THROTTLE BODY—8.0L ENGINE 58
PROCEDURE—3.9L/5.2L/5.9L ENGINES 56 THROTTLE POSITION SENSOR (TPS)—3.9L/
THROTTLE POSITION SENSOR (TPS)—3.9L/ 5.2L/5.9L ENGINES 58
5.2L/5.9L ENGINES 55 THROTTLE POSITION SENSOR (TPS)—8.0L
THROTTLE POSITION SENSOR (TPS)—8.0L ENGINE 58
ENGINE 55 VEHICLE S P E E D SENSOR 67
VEHICLE S P E E D SENSOR 55 SPECIFICATIONS
VISUAL INSPECTION—3.9L/5.2L/5.9L ENGINES . 43 TORQUE SPECIFICATIONS 67
VISUAL INSPECTION—8.0L ENGINE 46 VECI LABEL SPECIFICATIONS 67
REMOVAL AND INSTALLATION SPECIAL TOOLS
AIR CLEANER HOUSING/AIR CLEANER FUEL S Y S T E M 68
ELEMENT (FILTER)—3.9L/5.2L/5.9L ENGINES . 63
G E N E R A L INFORMATION and idle speed. The PCM can adapt its programming
to meet changing operating conditions.
INTRODUCTION P o w e r t r a i n C o n t r o l Module (PCM) I n p u t s rep
All engines are equipped with sequential Multi- resent the instantaneous engine operating conditions.
Port Fuel Injection (MFI). The M F I system provides Air-fuel mixture and ignition timing calibrations for
precise air/fuel ratios for all driving conditions. various driving and atmospheric conditions are pre
The powertrain control module (PCM) operates the programmed into the PCM. The PCM monitors and
fuel system. The PCM was formerly referred to as analyzes various inputs. I t then computes engine fuel
the SBEC or engine controller. The PCM (Fig. 1) is a and ignition timing requirements based on these
pre-programmed, dual microprocessor digital com inputs. Fuel delivery control and ignition timing will
puter. I t regulates ignition timing, air-fuel ratio, then be adjusted accordingly.
emission control devices, charging system, speed con Other inputs to the PCM are provided by the brake
trol, air conditioning compressor clutch engagement light switch, air conditioning select switch and the
14 - 26 FUEL SYSTEM — ^ ^ BR
The fuel injection system has the following modes
of operation:
© Ignition switch ON
• Engine start-up (crank)
© Engine warm-up
• Idle
• Cruise
• Acceleration
• Deceleration
• Wide open throttle (WOT)
• Ignition switch OFF
The ignition switch On, engine start-up (crank),
engine warm-up, acceleration, deceleration and wide
open throttle modes are Open Loop modes. The idle
and cruise modes, (with the engine at operating tem
perature) are Closed Loop modes.
mrnmom SWITCH ffccF-onJ MODE
speed control switches. A l l Inputs to the PCM are
This is an Open Loop mode. When the fuel system
converted Into signals.
is activated by the Ignition switch, the following
Electrically operated fuel Injectors spray fuel in
actions occur:
precise metered amounts Into the intake port directly
• The powertrain control module (PCM) pre-posi-
above the Intake valve. The Injectors are fired in a
tions the Idle air control (IAC) motor.
specific sequence.by the PCM. The PCM maintains
• The PCM determines atmospheric air pressure
an air/fuel ratio of 14.7 to 1 by constantly adjusting
from the MAP sensor Input to determine basic fuel
injector pulse width. Injector pulse width is the
strategy.
length of time that the injector opens and sprays fuel
• The PCM monitors the engine coolant tempera
into the chamber. The PCM adjusts injector pulse
ture sensor input. The PCM modifies fuel strategy
width by opening and closing the ground path to the
based on this input.
Injector.
• Intake manifold air temperature sensor Input Is
Manifold absolute pressure (air density) and
monitored.
engine rpm (speed) are the primary inputs that
• Throttle position sensor (TPS) is monitored.
determine fuel injector pulse width. The PCM also
• The auto shutdown (ASD) relay Is energized by
monitors other inputs when adjusting air-fuel ratio.
the PCM for approximately three seconds.
• The fuel pump is energized through the fuel
MOtJES OF OPERATION
pump relay by the PCM. The fuel pump will operate
As input signals to the powertrain control module
for approximately three seconds unless the engine is
(PCM) change, the PCM adjusts Its response to the operating or the starter motor is engaged.
output devices. For example, the PCM must calculate
• The 02S sensor heater element is energized
different Injector pulse width and ignition timing for
through the fuel pump relay. The 02S sensor Input Is
idle than i t does for wide open throttle (WOT). not used by the PCM to calibrate air-fuel ratio dur
The PCM will operate In two different modes: ing this mode of operation.
Open Loop and Closed Loop.
During Open Loop modes, the powertrain control ENGINE START-UP MODE
module (PCM) receives Input signals and responds This is an Open Loop mode. The following actions
only according to preset PCM programming. Input occur when the starter motor Is engaged.
from the oxygen (02S) sensors is not monitored dur The powertrain control module (PCM) receives
ing Open Loop modes. inputs from:
During Closed Loop modes, the PCM will monitor • Battery voltage
the oxygen (02S) sensors Input. This Input indicates • Engine coolant temperature sensor
to the PCM whether or not the calculated Injector • Crankshaft position sensor
pulse width results in the ideal air-fuel ratio. This • Intake manifold air temperature sensor
ratio Is 14.7 parts air-to-1 part fuel. By monitoring • Manifold absolute pressure (MAP) sensor
the exhaust oxygen content through the 02S sensor, • Throttle position sensor (TPS)
the PCM can fine tune the injector pulse width. This ® Starter motor relay
is done to achieve optimum fuel economy combined • Camshaft position sensor signal
with low emission engine performance.
BR FUEL SYSTE1 14 - 27

The PCM monitors the crankshaft position sensor. • Intake manifold air temperature sensor
I f the PCM does not receive a crankshaft position • Manifold absolute pressure (MAP) sensor
sensor signal within 8 seconds of cranking the ® Throttle position sensor (TPS)
engine, It will shut down the fuel injection system. • Camshaft position sensor signal (in the distribu
The fuel pump is activated by the PCM through tor)
the fuel pump relay. • Battery voltage
Voltage is applied to the fuel injectors with the • Park/neutral switch (gear indicator signal—auto,
PCM. The PCM will then control the injection trans, only)
sequence and injector pulse width by turning the • Oxygen sensors
ground circuit to each individual injector on and off. Based on these inputs, the following occurs:
The PCM determines the proper ignition timing • Voltage is applied to the fuel injectors with the
according to input received from the crankshaft posi powertrain control module (PCM). The PCM will
tion sensor. then control injection sequence and injector pulse
width by turning the ground circuit to each individ
ENGINE WARM-UP MODE ual injector on and off.
This Is an Open Loop mode. During engine warm- • The PCM monitors the 0 2 S sensor input and
up, the powertrain control module (PCM) receives adjusts air-fuel ratio by varying injector pulse width.
inputs from: It also adjusts engine idle speed through the idle air
• Battery voltage control (IAC) motor.
• Crankshaft position sensor • The PCM adjusts ignition timing by increasing
• Engine coolant temperature sensor and decreasing spark advance.
• Intake manifold air temperature sensor • The PCM operates the A/C compressor clutch
• Manifold absolute pressure (MAP) sensor through the clutch relay. This happens i f A/C has
• Throttle position sensor (TPS) been selected by the vehicle operator and requested
• Camshaft position sensor signal (in the distribu by the A/C thermostat.
tor)
• Park/neutral switch (gear indicator signal—auto, CRUISE MODE
trans, only) When the engine is at operating temperature, this
• Air conditioning select signal (if equipped) is a Closed Loop mode. At cruising speed, the power-
• Air conditioning request signal (if equipped) train control module (PCM) receives inputs from:
Based on, these inputs the following occurs: • Air conditioning select signal (if equipped)
• Voltage Is applied to the fuel injectors with the © Air conditioning request signal (if equipped)
powertrain control module (PCM). The PCM will • Battery voltage
then control the injection sequence and injector pulse • Engine coolant temperature sensor
width by turning the ground circuit to each individ • Crankshaft position sensor
ual injector on and off. • Intake manifold air temperature sensor
• The PCM adjusts engine idle speed through the • Manifold absolute pressure (MAP) sensor
idle air control (IAC) motor and adjusts ignition tim • Throttle position sensor (TPS)
ing. • Camshaft position sensor signal (in the distribu
• The PCM operates the A/C compressor clutch tor)
through the clutch relay. This is done i f A/C has been • Park/neutral switch (gear indicator signal—auto,
selected by the vehicle operator and requested by the trans, only)
A/C thermostat. • Oxygen (02S) sensors
• When engine has reached operating tempera Based on these inputs, the following occurs:
ture, the PCM will begin monitoring 02S sensor • Voltage is applied to the fuel injectors with the
input. The system will then leave the warm-up mode PCM. The PCM will then adjust the injector pulse
and go into closed loop operation. width by turning the ground circuit to each individ
ual injector on and off.
IDLE MODE • The PCM monitors the 02S sensor input and
When the engine is at operating temperature, this adjusts air-fuel ratio. I t also adjusts engine idle
is a Closed Loop mode. At idle speed, the powertrain speed through the idle air control (IAC) motor.
control module (PCM) receives inputs from: • The PCM adjusts ignition timing by turning the
• Air conditioning select signal (if equipped) ground path to the coil on and off.
• Air conditioning request signal (if equipped) • The PCM operates the A/C compressor clutch
• Battery voltage through the clutch relay. This happens i f A/C has
• Crankshaft position sensor been selected by the vehicle operator and requested
• Engine coolant temperature sensor by the A/C thermostat.
14-28 FUEL SYSTEM BR

ACCELERATION MODE • Voltage is applied to the fuel injectors with the
This is an Open Loop mode. The powertrain control powertrain control module (PCM). The PCM will
module (PCM) recognizes an abrupt Increase in then control the injection sequence and injector pulse
throttle position or MAP pressure as a demand for width by turning the ground circuit to each individ
increased engine output and vehicle acceleration. The ual injector on and off. The PCM ignores the oxygen
PCM increases injector pulse width in response to sensor input signal and provides a predetermined
increased throttle opening. amount of additional fuel. This is done by adjusting
injector pulse width.
DECELERATION MODE • The PCM adjusts ignition timing by turning the
When the engine is at operating temperature, this ground path to the coil on and off.
is an Open Loop mode. During hard deceleration, the • The PCM opens the ground circuit to the A/C
powertrain control module (PCM) receives the follow clutch relay to disengage the A/C compressor clutch.
ing inputs. This will be done for approximately 15 seconds (if the
• Air conditioning select signal (if equipped) air conditioning system is operating).
• Air conditioning request signal (if equipped)
• Battery voltage IGNITION SWITCH OFF MODE
• Engine coolant temperature sensor When ignition switch is turned to OFF position,
• Crankshaft position sensor the PCM stops operating the injectors, ignition coil,
• Intake manifold air temperature sensor ASD relay and fuel pump relay.
• Manifold absolute pressure (MAP) sensor
• Throttle position sensor (TPS)
• Camshaft position sensor signal (in the distribu DESCRIPTION AND OPERATION
tor)
• Park/neutral switch (gear indicator signal—auto, SYSTEM DIAGNOSIS
trans, only) The PCM can test many of its own input and out
I f the vehicle is under hard deceleration with the put circuits. I f the PCM senses a fault in a major
proper rpm and closed throttle conditions, the PCM system, the PCM stores a Diagnostic Trouble Code
will ignore the oxygen sensor input signal. The PCM (DTC) in memory.
will enter a fuel cut-off strategy in which i t will not Technicians can display stored DTCs by two differ
supply battery voltage to the injectors. I f a hard ent methods. The first is to cycle the ignition switch
deceleration does not exist, the PCM will determine On - Off - On - Off - On within 5 seconds. Then count
the proper injector pulse width and continue injec the number of times the malfunction indicator (check
tion. engine) lamp on the instrument panel flashes on and
Based on the above inputs, the PCM will adjust off. The number of flashes represents the DTC. There
engine idle speed through the idle air control (IAC) is a slight pause between the flashes representing
motor. the first and second digits of the code. Longer pauses
The PCM adjusts ignition timing by turning the separate individual trouble codes.
ground path to the coil on and off. The second method of reading DTCs uses the DRB
The PCM opens the ground circuit to the A/C scan tool. For DTC information, refer to Group 25,
clutch relay to disengage the A/C compressor clutch. Emission Control Systems. See On-Board Diagnos
This is done until the vehicle is no longer under tics.
deceleration (if the A/C system is operating).
POWERTRAIN CONTROL MODULE (PCM)
WIDE OPEN THROTTLE MODE The powertrain control module (PCM) (Fig. 1) oper
This is an Open Loop mode. During wide open ates the fuel system. The PCM was formerly referred
throttle operation, the powertrain control module to as the SBEC or engine controller. The PCM is a
(PCM) receives the following inputs. pre-programmed, dual microprocessor digital com
• Battery voltage puter. I t regulates ignition timing, air-fuel ratio,
• Crankshaft position sensor emission control devices, charging system, speed con
• Engine coolant temperature sensor trol, air conditioning compressor clutch engagement
• Intake manifold air temperature sensor and idle speed. The PCM can adapt its programming
• Manifold absolute pressure (MAP) sensor to meet changing operating conditions.
• Throttle position sensor (TPS) The PCM receives input signals from various
• Camshaft position sensor signal (in the distribu switches and sensors. Based on these inputs, the
tor) PCM regulates various engine and vehicle operations
During wide open throttle conditions, the following through different system components. These compo
occurs: nents are referred to as Powertrain Control Module
BR FUEL SYSTEM 14 29
(PCM) Outputs. The sensors and switches that pro • Ignition coil
vide Inputs to the PCM are considered Powertrain © EVAP canister purge solenoid
Control Module (PCM) Inputs. • SCI transmit (DRB scan tool connection)
The PCM adjusts Ignition timing based upon • Speed control vacuum solenoid
inputs It receives from sensors that react to: engine ® Speed control vent solenoid
rpm, manifold absolute pressure, engine coolant tem • Tachometer (on instrument panel, If equipped)
perature, throttle position, transmission gear selec The powertrain control module (PCM) contains a
tion (automatic transmission), vehicle speed and the voltage convertor. This converts battery voltage to a
brake switch. regulated 5.0 volts. I t Is used to power the crankshaft
The PCM adjusts idle speed based on inputs i t position sensor, camshaft position sensor and vehicle
receives from sensors that react to: throttle position, speed sensor. The PCM also provides a five (5) volt
vehicle speed, transmission .gear selection, engine supply for the manifold absolute pressure (MAP) sen
coolant temperature and from Inputs i t receives from sor and throttle position sensor (TPS).
the air conditioning clutch switch and brake switch.
Based on inputs that i t receives, the PCM adjusts AIR CONDITIONING (A/C) CONTROLS—PCM INPUT
ignition coil dwell. The PCM also adjusts the gener The A/C control system information applies to fac
ator charge rate through control of the generator tory installed air conditioning units.
field and provides speed control operation. A/C SELECT SIGNAL: When the A/C switch is in
the ON position, an input signal Is sent to the pow
NOTE: PCM Inputs; ertrain control module (PCM). The signal Informs the
PCM that the A/C has been selected. The PCM
• Generator output adjusts Idle speed to a pre-programmed rpm through
© A/C request (if equipped with factory A/C) the idle air control (IAC) motor to compensate for
@ A/C select (if equipped with factory A/C) Increased engine load.
• Auto shutdown (ASD) sense A/C REQUEST SiGMAL: Once A/C has been
• Intake manifold air temperature sensor selected, the powertrain control module (PCM)
• Battery voltage receives the A/C request signal from the evaporator
• Brake switch switch. The input indicates that the evaporator tem
• Engine coolant temperature sensor perature is in the proper range for A/C application.
• Crankshaft position sensor The PCM uses this input to cycle the A/C compressor
• Ignition circuit sense (Ignition switch in run clutch (through the A/C relay). I t will also determine
position) the correct engine idle speed through the Idle air con
• Manifold absolute pressure (MAP) sensor trol (IAC) motor position.
® Overdrive/override switch If the A/C low-pressure switch opens (Indicating a
• Oxygen sensor low refrigerant level), the PCM will not receive an
• Park/neutral switch (auto, trans, only) A/C receive signal. The PCM will then remove the
© SCI receive (DRB scan tool connection) ground from the A/C relay. This will deactivate the
• Speed control resume switch A/C compressor clutch.
• Speed control set switch If the evaporator switch opens, (indicating that
• Speed control on/off switch evaporator is. not In proper temperature range), the
• Camshaft position sensor signal PCM will not receive the A/C request signal. The
• Throttle position sensor PCM will then remove the ground from the A/C relay,
• Vehicle speed sensor deactivating the A/C compressor clutch.
• Sensor return
© Power ground AUTOMATIC SHUTDOWN (ASD) RELAY—PCM
• Signal ground INPUT
NOTE: PCM Outputs; A 12 volt signal at this input indicates to the PCM
that the ASD has been activated. The ASD relay is
• A/C clutch relay located in the Power Distribution Center (PDC) (Fig.
• Idle air control (IAC) motor 2). Refer to label on PDC cover for relay location. The
• Auto shutdown (ASD) relay relay is used to connect the oxygen sensor heater ele
© Generator field ment, ignition coil, generator field winding and fuel
• Malfunction indicator lamp (Check engine lamp) injectors to 12 volt + power supply.
• EGR valve control solenoid This input is used only to sense that the ASD relay
• Fuel injectors is energized. I f the powertrain control module (PCM)
• Fuel pump relay does not see 12 volts at this input when the ASD
cating that the brakes are being applied. After
receiving this input, the PCM maintains idle speed to
a scheduled rpm through control of the idle air con
trol (IAC) motor. The brake switch input is also used
to operate the speed control system.
CAMSHAFT POSITION SENSOR—3.9L/5.2L/5.9L

ENGINES—PCM INPUT
A sync signal is provide by the camshaft position
sensor located in the distributor (Fig. 3). The sync
signal from this sensor works in conjunction with the
crankshaft position sensor to provide the powertrain
control module (PCM) with inputs. This is done to
establish and maintain correct injector firing order.
Refer to Camshaft Position Sensor in Group 8D,
Ignition System for more information.
Fig. 2 Power Distribution Center (PDC)
should be activated, it will set a diagnostic trouble
code (DTC).
BATTERY TEMPERATURE SENSOR—PCM INPUT

Provides a signal to the PCM corresponding to the
battery temperature. Refer to Group 8G, Charging
System for additional information.
BATTERY VOLTAGE—PCM INPUT

The battery voltage input provides power to the
powertrain control module (PCM). I t also informs the
PCM what voltage level Is supplied to the ignition
coll and fuel injectors.
I f battery voltage is low, the PCM will increase
injector pulse width (period of time that the injector
is energized). This Is done to compensate for the Fig. 3 Camshaft Position Sensor—3.9L/5.2U5.9L
reduced flow through injector caused by the lowered Engines
voltage.
CAMSHAFT POSITION SENSOR—8.0L ENGINE—
FIWE WOLI SENSOR SUPPLY—PRIMARY PCM INPUT
Supplies the required 5 volt power source to the A sync signal is provide by the camshaft position
crankshaft position sensor, camshaft position sensor, sensor. The sensor is located on the side of the timing
MAP sensor and throttle position sensor. chain case/cover (Fig. 4). The sync signal from this
sensor works in conjunction with the crankshaft posi
FIVE VOLT SENSOR SUPPLY—SECONDARY tion sensor to provide the powertrain control module
Supplies the required 5 volt power source to the (PCM) with inputs. This is done to establish and
transmission pressure sensor and the vehicle speed maintain correct injector firing order.
sensor. Refer to Camshaft Position Sensor in Group 8D,
Ignition System for more information.
FUEL LEVEL SENSOR—PCM INPUT
The fuel level sensor sends a variable voltage to CRANKSHAFT POSITION SENSOR—3.9L/5.2L/5.9L
the PCM to indicate fuel level. The purpose of this ENGINES—PCM INPUT
feature is to prevent a false setting of misfire and This sensor is a hall effect device that detects
fuel system monitor trouble codes i f the fuel level is notches in the flywheel (manual transmission) or
less than 15 percent of its rated capacity. flexplate (automatic transmission).
This sensor is used to indicate to the powertrain
BRAKE SWITCH—PCM INPUT control module (PCM) that a spark and or fuel injec
When the brake light switch is activated, the pow tion event is to be required. The output from this
ertrain control module (PCM) receives an input indi

It is used to indicate to the .powertrain control
module (PCM) that a spark and or fuel Injection
event is to be required. The output from this sensor,
in conjunction with the camshaft position -sensor sig
nal, Is used to differentiate between fuel injection
and spark events. I t Is also used to synchronize the
fuel injectors with their respective cylinders.
The sensor is bolted to the side of the cylinder
block (Fig. 6).
Fig. 4 Camshaft Position Sensor—8.0L Engine

sensor, in conjunction with the camshaft position sen
sor signal, is used to differentiate between fuel Injec
tion and spark events. I t Is also used to synchronize
the fuel injectors with their respective cylinders.
The sensor is bolted to the cylinder block near the
rear of the right cylinder head (Fig. 5).
Fig. § Crankshaft Position Sensor—8.0L Engine—

Typical
Refer to Group 8D, Ignition System' for more
crankshaft position sensor Information.
receive a crankshaft position sensor input. *
ENGINE COOLANT TEMPERATURE SENSOR—3.9L/

5.2L/5.9L ENGINES—PCM INPUT
The engine coolant temperature sensor is installed
next to the thermostat housing (Fig. 7) and protrudes
into the water jacket. The sensor provides an input
voltage to the powertrain control module (PCM)
relating coolant - temperature. The PCM uses this
input along with inputs from other sensors to deter
mine injector pulse width and' Ignition timing. As
coolant temperature varies, the coolant temperature
sensor resistance will change. This change i n resis
tance results i n a different input voltage to the PCM.
Fig. 5 Crankshaft Position Sensor—3.9U5.2U5.9L
When the - -engine is cold, * the PCM will operate in
Engines—Typicat
Open Loop cycle. I t will demand slightly richer air-
Refer to Group 8D, Ignition System for more fuel mixtures and higher idle speeds. This Is done
crankshaft position sensor information. until normal operating temperatures are reached.
receive a crankshaft position sensor input. ENGINE COOLANT TEMPERATURE SENSOR—8 J L
ENGINE—PCM INPUT
CRANKSHAFT POSITION SENSOR—8.0L The engine coolant temperature sensor Is installed
ENGINE—PCM INPUT In the thermostat housing (Fig. 8) and protrudes into
This sensor is a hall effect device that detects the water jacket. The sensor provides an Input volt
notches in the engine crankshaft. age to the powertrain control module (PCM) relating
DESCRIPTION AND OPERATION. (Continued)
mixture) i t produces a higher voltage. By monitoring
the oxygen content and converting i t to electrical
voltage, the sensors act as a rich-lean switch.
The oxygen sensors are equipped with a heating
element that keeps the sensors at proper operating
temperature during all operating modes. Maintaining
correct sensor temperature at all times allows the
system to enter into closed loop operation sooner.
Also, i t allows the system to remain in closed loop
operation during periods of extended idle.
In Closed Loop operation, the PCM monitors the
02S sensor input (along with other inputs) and
adjusts the injector pulse width accordingly. During
Open Loop operation, the PCM ignores the 02 sensor
input. The PCM adjusts injector pulse width based
on preprogrammed (fixed) values and inputs from
Fig. 7 Engine Coolant Temperature Sensor—3.9U other sensors.
5.2U5.9L Engines—Typical The Automatic Shutdown (ASD) relay supplies bat
tery voltage to both the upstream and downstream
coolant temperature. The PCM uses this input along heated oxygen sensors. The oxygen sensors are
with inputs from other sensors to determine injector equipped with a heating element. The heating ele
pulse width and ignition timing. As coolant tempera ments reduce the time required for the sensors to
ture varies, the coolant temperature sensor resis reach operating temperature.
tance will change. This change in resistance results
in a different input voltage to the PCM. UPSTREAM HEATED OXYGEN SENSOR
When the engine is cold, the PCM will operate in The upstream 02S sensor is located i n the exhaust
Open Loop cycle. I t will demand slightly richer air- downpipe (Fig. 9). I t provides an input voltage to the
fuel mixtures and higher idle speeds. This is done PCM. The input tells the PCM the oxygen content of
until normal operating temperatures are reached. the exhaust gas. The PCM uses this information to
fine tune fuel delivery to maintain the correct oxygen
content at the downstream oxygen sensor. The PCM
will change the air/fuel ratio until the upstream sen
sor inputs a voltage that the PCM has determined
will make the downstream sensor output (oxygen
content) correct.
The upstream oxygen sensor also provides an input
to determine catalyst efficiency. Refer to Group 25
Emissions, On-Board Diagnostics, Catalyst Monitor
DOWNSTREAM HEATED OXYGEN SENSOR

The downstream heated oxygen sensor is located
near the outlet end of the catalytic convertor (Fig. 9).
The downstream is also used to determine the correct
air fuel ratio. As the oxygen content changes at the
downstream the PCM calculates how much air fuel
Fig. 8 Engine Coolant Temperature Sensor—8.0L
ratio change is required. The PCM then looks at the
Engine—Typical
upstream oxygen sensor voltage and changes fuel
HEATED OXYGEN SENSOR (02S)—3.9L/5.2L/5.9L delivery until the upstream sensor voltage changes
LDC ENGINES—PCM INPUT enough to correct the downstream sensor voltage
Two heated 02S sensors are used (upstream and (oxygen content).
downstream). The sensors produce voltages from 0 to The downstream oxygen sensor also provides an
1 volt, depending upon the oxygen content of the input to determine catalyst efficiency. Refer to Group
exhaust gas in the exhaust manifold. When a large 25 Emissions Control Systems, On-Board Diagnos
amount of oxygen is present (caused by a lean air/ tics, Catalyst Monitor for more information.
fuel mixture), the sensors produces a low voltage.
When there is a lesser amount present (rich air/fuel
DOWN STREAM UP STREAM

OXYGEN OXYGEN
SENSOR SENSOR
Fig. 9 Upstream/Downstream Oxygen Sensors—

Pig. 10 Left/Right Heated Oxygen Sensors—HDC
LDC Engines
Engines
HEATED OXYGEN SENSOR (02S)—HDC
HEATED OXYGEN SENSOR (02S)—8.0L I D C
ENGINES—PCM INPUT
ENGINES—PCM INPUT
A total of two heated 02S sensors are used (left
The 8.0L V-10 engine, when equipped with a
and right) on HDC engines. On the 5.9L HDC
Medium Duty Emission Cycle (MDC) package, will
engine, the left 02S sensor will monitor cylinders 1,
use four heated 02S sensors. They are: Left, right,
3, 5 and 7. The right sensor will monitor cylinders 2,
pre-catalyst and post catalyst. The left, right and
4, 6 and 8. On the 8.0L V-10 HDC engine, the left
post catalyst sensors will fine-tune air-fuel ratio. The
02S sensor will monitor cylinders 1, 3, 5, 7 and 9.
pre-catalyst and post catalyst sensors will determine
The right sensor will monitor cylinders 2, 4, 6, 8 and
catalytic converter efficiency.
10.
Two of these sensors are installed into the left and
The sensors produce voltages from 0 to 1 volt,
right exhaust manifold downpipes (Fig. 10). On the
depending upon the oxygen content of the exhaust
8.0L V-10 MDC engine, the left 02S sensor will mon
gas in the exhaust manifold. When a large amount of
itor cylinders 1, 3, 5, 7 and 9. The right sensor will
oxygen is present (caused by a lean air/fuel mixture),
monitor cylinders 2, 4, 6, 8 and 10.
the sensors produces a low voltage. When there is a
The sensors produce voltages from 0 to 1 volt,
lesser amount present (rich air/fuel mixture) It pro
depending upon the oxygen content of the exhaust
duces a higher voltage. By monitoring the oxygen
gas in the exhaust manifold. When a large amount of
content and converting It to electrical voltage, the
oxygen is present (caused by a lean air/fuel mixture),
sensors act as a rich-lean switch.
the sensors produces a low voltage. When there is a
lesser amount present (rich air/fuel mixture) i t pro
duces a higher voltage. By monitoring the oxygen
content and converting i t to electrical voltage, the
sensors act as a rich-lean switch.
Also, it allows the system to remain In closed loop
operation during periods of extended Idle.
02S sensor Input (along with other inputs) and
adjusts the Injector pulse width accordingly. During
Also, it allows the system to remain i n closed loop
operation during periods of extended idle.
input. The PCM adjusts Injector pulse width based
02S sensor input (along with other inputs) and
other sensors.
adjusts the injector pulse width accordingly. During
The Automatic Shutdown (ASD) relay supplies bat
tery voltage to both oxygen sensors. The oxygen sen
input. The PCM adjusts injector pulse width based
sors are equipped with a heating elements. The
heating elements reduce the time required for the
other sensors.
sensors to reach operating temperature.
The Automatic Shutdown (ASD) relay supplies bat INTAKE MANIFOLD AIR TEMPERATURE SENSOR—
tery voltage to both oxygen sensors. The oxygen sen 3.9L/5.2L/5.9L ENGINES—PCM INPUT
sors are equipped with a heating elements. The The intake manifold air temperature sensor is
heating elements reduce the time required for the installed in the intake manifold with the sensor ele
sensors to reach operating temperature. ment extending into the air stream (Fig. 12) or (Fig.
13). The sensor provides an input voltage to the pow
PRE-CATALYST OXYGEN SENSOR
ertrain control module (PCM) indicating intake man
The pre-catalyst 02S sensor is located in the inlet
ifold air temperature. The input is used along with
end of the catalytic converter (Fig. 11). I t provides an
inputs from other sensors to determine injector pulse
input voltage to the PCM. By comparing the input
width. As the temperature of the air-fuel stream in
from the pre-catalyst 02S sensor, with the input
the manifold varies, the sensor resistance changes.
from the post catalyst oxygen sensor, the PCM calcu
This results in a different input voltage to the PCM.
lates catalytic convertor efficiency.
POST CATALYST PRE-CATALYST

OXYGEN OXYGEN
805dd850
Fig. 12 Intake Manifold Air Temperature Sensor—

Fig. 11 Pre-Catalyst/Post Catalyst Oxygen
3.9L Engine—Typical
Sensors—MDC Engines
POST CATALYST OXYGEN SENSOR
The post catalyst heated oxygen sensor threads
into the outlet end of the catalytic convertor (Fig. 11).
The post catalyst heated oxygen sensor input is used
to detect catalytic convertor deterioration and fine
tune the air fuel ratio. As the convertor deteriorates,
the input from this sensor begins to match the pre-
catalyst sensor input except for a slight time delay.
By comparing the inputs from both of these sensors,
the PCM calculates catalytic convertor efficiency.
When the catalytic converter efficiency drops below
emission standards, the PCM stores a diagnostic
trouble code and illuminates the Malfunction Indica
tor Lamp (MIL). For more information, refer to
Group 25, Emission Control Systems.
IGNITION CIRCUIT SENSE—PCM INPUT
5.2U5.9L Engines—Typical
The ignition circuit sense input tells the Power-
train Control Module (PCM) the ignition switch has INTAKE MANIFOLD AIR TEMPERATURE SENSOR—
energized the ignition circuit. Refer to the wiring dia 8.0L ENGINE—PCM INPUT
grams for circuit information. The intake manifold air temperature sensor is
installed in the intake manifold with the sensor ele
ment extending into the air stream (Fig. 14). The
sensor provides an input voltage to the powertrain
mm FUEL SYSTEM 14 - 35

control module (PCM) indicating intake manifold air
temperature. The input is used along with inputs
from other sensors to determine injector pulse width.
As the temperature of the air-fuel stream In the
manifold varies, the sensor resistance changes. This
results In a different input voltage to the PCM.
Fig. 15 MAP and Throttle Position Sensor

Fig. 14 intake Manifold Air Temperature Sensor—
8.0L Engine—Typical Location—3.9U5.2U5.9L Engines—Typical
ning. The PCM uses this input along with inputs
MANIFOLD ABSOLUTE PRESSURE (MAP)
from other sensors to adjust air-fuel mixture.
SENSOR—3.9L/5.2L/5.9L ENGINES—PCM INPUT The MAP sensor is mounted into the right side of
The MAP sensor reacts to absolute pressure in the the intake manifold. (Fig. 16).
intake manifold. It provides an input voltage to the
powertrain control module (PCM). As engine load
changes, manifold pressure varies. The change in
manifold pressure causes MAP sensor voltage to
change. The change in MAP sensor voltage results in
a different input voltage to the PCM. The input volt
age level supplies the PCM with information about
ambient barometric pressure during engine start-up
(cranking) and engine load while the engine is run
ning. The PCM uses this input along with inputs
from other sensors to adjust air-fuel mixture.
The MAP sensor is mounted on the side of the
engine throttle body (Fig. 15). The sensor is con
nected to the throttle body with a rubber L-shaped
fitting.

SENSOR—8.0L ENGINE—PCM INPUT Fig. 16 MAP Sensor Location—8.OL Engine—Typical
The MAP sensor reacts to absolute pressure i n the
intake manifold. I t provides an input voltage to the OUTPUT SHAFT SPEED SENSOR—PCM INPUT
powertrain control module (PCM). As engine load
changes, manifold pressure varies. The change in This sensor generates a signal to the PCM relating
manifold pressure causes MAP sensor voltage to to the speed of the transmission main drive shaft.
change. The change in MAP sensor voltage results in This input is used with 4-speed electronic transmis
a different input voltage to the PCM. The input volt sions only. Also refer to Vehicle Speed Sensor—PCM
Input for additional information.
age level supplies the PCM with information about
ambient barometric pressure during engine start-up
(cranking) and engine load while the engine is run-
OVERDRIVE/OVERRIDE SWITCH-PCM INPUT the variable force solenoid, which regulates transmis
On vehicles equipped with an automatic transmis sion governor pressure. This input is used with
sion and overdrive, the powertrain control module 4-speed electronic transmissions only.
(PCM) regulates the 3-4 overdrive up-shift and down
shift through the overdrive solenoid. This solenoid is TRANSMISSION TEMPERATURE SENSOR—PCM
located In the transmission. An overdrive/override INPUT
push-button switch is located on the instrument This input is used in the shift operation for
panel. 4-speed electronic transmissions only. The tempera
The PCM circuit for overdrive is controlled by ture data is used for: torque converter clutch opera
Inputs from the engine coolant temperature sensor tion, overdrive shift, low temperature shift
and vehicle speed sensor. I f coolant temperature and compensation, wide open throttle shift strategy and
vehicle speed are not within the preset PCM specifi governor pressure transducer calibration.
cations, the PCM will not allow the transmission to
shift into overdrive. These preset PCM specifications TRANSMISSION PRESSURE SENSOR—PCM INPUT
must be met before the push-button switch will be Provides a signal proportional to the transmission
allowed to control overdrive operation. governor pressure. I t provides feedback for control of
The overdrive/override push-button switch is nor the variable force solenoid, which regulates transmis
mally closed (overdrive allowed) when the lamp Is sion governor pressure. This is used with 4-speed
not illuminated. I t opens (overdrive not allowed) automatic transmissions only.
when the operator presses the switch and the lamp is
illuminated. The switch will revert to its normally THROTTLE POSITION SENSOR (TPS)—3.9L/5.2L/
closed position (lamp off) each time the ignition 5.9L ENGINES—PCM INPUT
switch In turned on. The transmission downshifts i f The throttle position sensor (TPS) is mounted on
the operator presses the override switch while in the throttle body (Fig. 15). The TPS is a variable
overdrive. resistor that provides the powertrain control module
Refer to Group 21 for more transmission informa (PCM) with an input signal (voltage) that represents
tion. throttle blade position. The sensor is connected to the
throttle blade shaft. As the position of the throttle
SPEED CONTROL SWITCH—PCM INPUT blade changes, the resistance of the TPS changes.
Six different speed control functions, using three The PCM supplies approximately 5 volts to the
momentary contact switches, are monitored through TPS. The TPS output voltage (input signal to the
this multiplexed input. The resistance monitored at PCM) represents the throttle blade position. The
this input, in combination with the length of time the PCM receives an input signal voltage from the TPS.
PCM measures the resistance, determines which This will vary in an approximate range of from 1 volt
switch feature has been selected. The three switches at minimum throttle opening (idle), to 4 volts at wide
are: On/Off, Set/Coast and Resume/Accelerate. open throttle. Along with inputs from other sensors,
Refer to Group 8H, Vehicle Speed Control System the PCM uses the TPS input to determine current
for further speed control information. engine operating conditions. I n response to engine
operating conditions, the PCM will adjust fuel injec
TRANSMISSION PARK/NEUTRAL SWITCH—PCM tor pulse width and ignition timing.
INPUT
The park/neutral switch Is located on the transmis THROTTLE POSITION SENSOR (TPS)—8.0L
sion housing and provides an input to the powertrain ENGINE—PCM INPUT
control module (PCM). This will indicate that the The throttle position sensor (TPS) is mounted on
automatic transmission is in Park, Neutral or a drive the throttle body (Fig. 17). The TPS is a variable
gear selection. This input is used to determine idle resistor that provides the powertrain control module
speed (varying with gear selection), fuel Injector (PCM) with an input signal (voltage) that represents
pulse width, ignition timing advance and vehicle throttle blade position. The sensor is connected to the
speed control operation. Refer to Group 21, Transmis throttle blade shaft. As the position of the throttle
sions, for testing, replacement and adjustment infor blade changes, the resistance of the TPS changes.
mation. The PCM supplies approximately 5 volts to the
TPS. The TPS output voltage (input signal to the
TRANSMISSION GOVERNOR PRESSURE PCM) represents the throttle blade position. The
SENSOR—PCM INPUT PCM receives an input signal voltage from the TPS.
Provides a signal proportional to the transmission This will vary in an approximate range of from 1 volt
governor pressure. I t provides feedback for control of at minimum throttle opening (idle), to 4 volts at wide

The speed sensor generates 8 pulses per sensor
revolution. These signals, in conjunction with a
closed throttle signal from the throttle position sen
sor, indicate a closed throttle deceleration to the
PCM. When the vehicle is stopped at idle, a closed
throttle signal is received by the PCM (but a speed
sensor signal is not received).
Under deceleration conditions, the PCM adjusts
the idle air control (IAC) motor to maintain a desired
MAP value. Under idle conditions, the PCM adjusts
the IAC motor to maintain a desired engine speed.
POWER GROUND
The power ground is used to control ground cir
cuits for the following powertrain control module
(PCM) loads:
Fig. 17 Sensor Location—8.0L Engine • Generator field winding
open throttle. Along with inputs from other sensors, • 8 volt (PCM) power supply
the PCM uses the TPS input to determine current • Fuel injectors
engine operating conditions. In response to engine • Ignition coil
operating conditions, the PCM will adjust fuel Injec
AIR CONDITIONING (A/C) CLUTCH RELAY—PCM
tor pulse width and ignition timing.
OUTPUT
VEHICLE SPEED AND DISTANCE SENSOR—PCM The A/C relay is located in the Power Distribution
INPUT Center (PDC) (Fig. 19). Refer to label on PDC cover
The vehicle speed sensor is located on the speed for relay location.
ometer pinion gear adapter (Fig. 18). The pinion gear
adapter is located on the extension housing of the
transmission (drivers side). The sensor input is used
by the powertrain control module (PCM) to deter
mine vehicle speed and distance traveled.
SENSOR
ELECTRICAL
CONNECTOR

The powertrain control module (PCM) activates the
A/C compressor through the A/C clutch relay. The
PCM regulates A/C compressor operation by switch
ing the ground circuit for the A/C clutch relay on and
off.
When the PCM receives a request for A/C from A/C
evaporator switch, i t will adjust idle air control (IAC)
J9414-60 motor position. This is done to increase idle speed.
The PCM will then activate the A/C clutch through
the A/C clutch relay. The PCM adjusts idle air control
Fig. 18 Vehicle Speed Sensor Location—Typical (IAC) stepper motor position to compensate for
increased engine load from the A/C compressor.
By switching the ground path for the relay on and DUTY CYCLE EVAP PURGE SOLENOID VALVE-PCM
off, the PCM is able to cycle the A/C compressor OUTPUT
clutch. This Is based on changes In engine operating Refer to Group 25, Emission Control System for
conditions. If, during A/C operation, the PCM senses information.
low Idle speeds or a wide open throttle condition, It
will de-energize the relay. This prevents A/C clutch FUEL INJECTORS—3.9L/5.2L/5.9L ENGINES—
engagement. The relay will remain de-energized until
PCM OUTPUT
the idle speed increases or the wide open throttle
The fuel injectors are attached to the fuel rail (Fig.
condition exceeds 15 seconds or no longer exists. The
21). 3.9L engines use six injectors. 5.2L and 5.9L
PCM will also de-energize the relay i f coolant tem
engines use eight injectors.
perature exceeds 125°C (257°F).
AUTO SHUTDOWN (ASD) RELAY-—PCM OUTPUT

The ASD relay is located in the Power Distribution
The ASD supplies battery voltage to the fuel pump,
fuel injector, ignition coil, generator field winding
and oxygen (02S) sensor heating element. The
ground circuit for the coil in the ASD relay is con
trolled by the powertrain control module (PCM). The
PCM operates the relay by switching the ground cir
cuit on and off.
The fuel pump relay is controlled by the PCM
through same circuit that the ASD relay is con
trolled.
DATA LINK CONNECTOR—PCM INPUT AND

OUTPUT
The 16-way data link connector (diagnostic scan
tool' connector) links the Diagnostic Readout Box
(DRB) scan tool or the Mopar Diagnostic System
(MDS) with the powertrain control module (PCM). INJECTOR J9214-30
The data link connector (Fig. 20) is located at lower
edge of instrument panel near steering column. For Fig. 21 Fuel Injectors—3.9U5.2U5.9L Engines-
operation of the DRB scan tool, refer to the appropri Typical
ate Powertrain Diagnostic Procedures service man The nozzle ends of the injectors are positioned into
ual. openings in the intake manifold just above the intake
valve ports of the cylinder head. The engine wiring
18-WAY DATA
LINK CONNECTOR
with an attached numerical tag (INJ 1, INJ 2 etc.).
This is used to identify each fuel injector with its
respective cylinder number.
The injectors are energized individually in a
sequential order by the powertrain control module
(PCM). The PCM will adjust injector pulse width by
switching the ground path to each individual injector
on and off. Injector pulse width is the period of time
that the injector is energized. The PCM will adjust
injector pulse width based on various inputs it
receives.
During start up, battery voltage is supplied to the
injectors through the ASD relay. When the engine is
805dd852
operating, voltage is supplied by the charging sys
Fig. 20 16-Way Data Link Connector tem. The PCM determines injector pulse width based
on various inputs.
FUEL INJECTORS—8.0L ENGINE—PCM OUTPUT Refer to Automatic Shutdown Relay—PCM Output
The fuel injectors are attached to the fuel rail (Fig. for additional information.
22). 8.0L V-10 engines use 10 Injectors. The fuel pump will operate for approximately one
second unless the engine is operating or the starter
ELECTRICAL MOUNTING motor is engaged.
CONNECTOR BOLTS (6)
The fuel pump relay is located in the Power Distri
bution Center (PDC) (Fig. 19).
GENERATOR FIELD—PCM OUTPUT

The powertrain control module (PCM) regulates
the charging system voltage within a range of 12.9 to
15.0 volts. Refer to Groups 8A and 8C for charging
system information.
GENERATOR LAMP—PCM OUTPUT

I f the powertrain control module (PCM) senses a
low charging condition in the charging system, i t will
illuminate the generator lamp (if equipped) on the
instrument panel. For example, during low idle with
all accessories turned on, the lamp may momentarily
go on. Once the PCM corrects idle speed to a higher
rpm, the lamp will go out. Refer to Groups 8A and
8C for charging system information.
IDLE AIR CONTROL (IAC) MOTOR—3.9L/5.2L/5.9L

ENGINES—PCM OUTPUT
Fig. 22 Fuel Injectors—8.0L Engine—Typical
The IAC motor is mounted to the back of the throt
The nozzle ends of the injectors are positioned into tle body (Fig. 15) and is controlled by the powertrain
openings in the intake manifold just above the intake control module (PCM).
valve ports of the cylinder head. The engine wiring The throttle body has an air control passage that
harness connector for each fuel injector is equipped provides air for the engine at idle (the throttle plate
with an attached numerical tag (INJ 1, INJ 2 etc.). is closed). The IAC motor pintle protrudes into the
This is used to identify each fuel injector with its air control passage (Fig. 23) and regulates air flow
respective cylinder number. through it. Based on various sensor inputs, the pow
The 10 injectors are energized individually in a ertrain control module (PCM) adjusts engine idle
sequential order by the powertrain control module speed by moving the IAC motor pintle in and out of
(PCM). The PCM will adjust injector pulse width by the air control passage. The IAC motor is positioned
switching the ground path to each individual injector when the ignition key is turned to the On position.
on and off. Injector pulse width is the period of time A (factory adjusted) set screw is used to mechani
that the injector is energized. The PCM will adjust cally limit the position of the throttle body throttle
injector pulse ' width based on various inputs i t plate. Never attempt to adjust the engine idle
receives. speed using this screw. All idle speed functions are
During start up, battery voltage is supplied to the controlled by the PCM.
injectors through the ASD relay. When the engine is
operating, voltage is supplied by the charging sys IDLE AIR CONTROL (IAC) MOTOR—8.0L
tem. The PCM determines injector pulse width based ENGINE—PCM OUTPUT
on various inputs. The IAC motor is mounted to the side of the throt
tle body (Fig. 24) and is controlled by the powertrain
FUEL PUMP RELAY-PCM OUTPUT control module (PCM).
The PCM energizes the electric fuel pump and the The throttle body has an air control passage that
oxygen sensor (02S) heating element through the provides air for the engine at idle (the throttle plate
fuel pump relay. Battery voltage is applied to the fuel is closed). The IAC motor pintle protrudes into the
pump relay when the ignition key is ON. The relay is air control passage (Fig. 25) * and regulates air flow
energized when a ground signal is provided by the through it. Based on various sensor inputs, the pow
PCM. ertrain control module (PCM) adjusts engine idle
speed by moving the IAC motor pintle in and out of

VACUUM
FITTING
Fig. 23 Throttle Body Air Control Passage—3.9U

5.2U5.9L Engines
PASSAGE CONTROL (IAC)
the air control passage. The IAC motor is positioned MOTOR
when the ignition key is turned to the On position. VIEW FROM BOTTOM ,
l Q A A A Q
A (factory adjusted) set screw is used to mechani

cally limit the position of the throttle body throttle Fig. 25 Idle Air Control Passage—8.0L Engine
plate. Never attempt to adjust the engine idle
speed using this screw. All idle speed functions are
controlled by the PCM.
Fig. 26 Ignition Coil—3.9U5.2U5.9L Engines-

Typical (3.9L Shown)
Fig. 24 Idle Air Control Motor Location—8.0L Engine IGNITION COILS—8.0L ENGINE—PCM OUTPUTS
System voltage is supplied to each of the five igni
IGNITION COIL—3.9L/5.2L/5.9L ENGINES—PCM
tion coil positive terminals. The powertrain control
OUTPUT module (PCM) operates the 5 paired ignition coils.
System voltage is supplied to the ignition coil pos Base (initial) ignition timing is not adjustable.
itive terminal. The powertrain control module (PCM) The PCM adjusts ignition timing to meet changing
operates the ignition coil. Base (initial) ignition engine operating conditions.
timing is not adjustable. The PCM adjusts ignition The ignition coil pack is located above the right
timing to meet changing engine operating conditions. engine valve cover (Fig. 27).
The ignition coil is located near the front of the Refer to Group 8D, Ignition System for additional
right cylinder head (Fig. 26). information.
Refer to Group 8D, Ignition System for additional
information.
BR

COILS The lamp is also used to detect certain engine mis
fires. Refer to Group 25, Emission Control System for
more information.
OVERDRIVE LAMP—PCM OUTPUT

This circuit controls a signal for the operation of
the instrument panel mounted push-button overdrive
lamp switch. When the lamp is illuminated, the over
drive is disengaged.
SPEED CONTROL SOLENOIDS—PCM OUTPUT

Speed control operation is regulated by the power-
train control module (PCM). The PCM controls the
ENGINE COIL vacuum to the throttle actuator through the speed
-CYLINDER^ "MOUNTING"
~ NUMBER BOLTS (8)
control vacuum and vent solenoids. Refer to Group
J948D-6
8H for Speed Control Information.
Fig. 27 ignition Coii Packs—8.0L Engine
SERVICE REMINDER INDICATOR (SRI) LAMP—
MALFUNCTION INDICATOR (CHEC1 EN01NE) PCM OUTPUT
LAMP—PCM OUTPUT This circuit controls operation of the SRI lamp.
The malfunction indicator lamp illuminates each The instrument panel mounted service reminder
time the ignition key is turned on. I t will stay on for indicator (SRI) lamp is used only on vehicles
approximately three seconds as a bulb test. The lamp equipped with 5.9L V-8 or 8.0L V-10 heavy duty cycle
is displayed on the instrument panel as the CHECK (HDC) engines. The lamp is displayed on the instru
ENGINE lamp (Fig. 28). ment panel as the MAINT REQ'D lamp (Fig. 29).
When the lamp has been activated, certain service/
TACHOMETER
maintenance must be performed.
For required service/maintenance stated in time or
mileage, refer to Group 0, Lubrication and Mainte
nance. Also refer to Group 25, Emission Control Sys
tem for additional information.
The SRI lamp is not used with diesel engines.
J9414-62
MAINT
Fig. 28 Check Engine Lamp Location—Typical REQD'
^ BRAKE
I f the powertrain control module (PCM) receives an
incorrect signal, or no signal from certain sensors or
emission related systems, the lamp is turned on. This
SERVICE REMINDER
is a warning that the PCM has recorded a system or INDICATOR LAMP
J9514-13
sensor malfunction. I n some cases, when a problem is
declared, the PCM will go into a limp-in mode. This
Fig. 29 SRI Lamp Location
is an attempt to keep the system operating. I t signals
an immediate need for service. TACHOMETER—PCM OUTPUT
The lamp can also be used to display a Diagnostic The powertrain control module (PCM) supplies
Trouble Code (DTC). Cycle the ignition switch engine rpm values to the instrument cluster tachom
On-Off-On-Off-On within three seconds and any eter. Refer to Group 8E for tachometer information. .
codes stored in the PCM memory will be displayed.
This is done in a series of flashes representing digits.
14 - 42 FUEL SYSTEM
THREE-FOUR SHIFT SOLENOID—PCM OUTPUT THROTTLE B O D Y — 3 . 9 L / 5 . 2 L / 5 . 9 L ENGINES

This output is used to control the transmission Filtered air from the air cleaner enters the intake
three-four shift solenoid. I t is used on 4-speed elec manifold through the throttle body (Fig. 30). Fuel
tronically controlled automatic transmissions only. does not enter the intake manifold through the throt
tle body. Fuel is sprayed into the manifold by the fuel
TORQUE CONVERTOR CLUTCH (TCC) SOLENOID— injectors. The throttle body is mounted on the intake
PCM OUTPUT manifold. I t contains an air control passage (Fig. 31)
This circuit controls operation of the transmission controlled by an idle air control (IAC) motor. The air
mounted torque convertor clutch (TCC) solenoid used control passage is used to supply air for idle condi
for torque convertor engagement. tions. A throttle valve (plate) is used to supply air for
The powertrain control module (PCM) will deter above idle conditions.
mine when to engage and disengage the solenoid by
monitoring vehicle miles per hour (mph) versus the THROTTLE BODY
output voltage of the throttle position sensor. Also
needed are various Inputs from:
• Engine coolant temperature
• Module timer
• Engine rpm
• MAP sensor
MANUAL TRANSMISSION
I f equipped with a manual transmission, this PCM
output will control operation of the shift indicator
lamp (if equipped with lamp). The lamp Is controlled
by the powertrain control module (PCM). The lamp
Illuminates on the instrument panel to indicate when
the driver should shift to the next highest gear for
best fuel economy. The PCM will turn the lamp OFF
after 3 to 5 seconds i f the shift of gears is not per
formed. The lamp will remain off until vehicle stops
accelerating and is brought back to range of up-shift
lamp operation. This will also happen i f vehicle Is
shifted into fifth gear.
The indicator lamp is normally illuminated when Fig. 30 Throttle Body—3.9L/5.2L/5.9L Engines
the ignition switch is turned on and i t is turned off
when the engine is started up. With the engine run
ning, the lamp is turned ON/OFF depending upon
engine speed and load.
TRANSMISSION R E L A Y — P C I OUTPUT
The output to this relay provides battery voltage to
the overdrive (OD), torque converter clutch (TCC)
and variable force (VSS) solenoids. Once battery volt
age Is applied to the solenoids, they are Individually
activated by the PCM through OD, TCC and VSS
outputs. The relay is located In the Power Distribu
tion Center (PDC). Refer to label on PDC cover for
relay location.
VARIABLE FORCE SOLENOID—PCM OUTPUT

This solenoid regulates the transmission fluid line
pressure to produce the governor pressure necessary
Fig. 31 Air Control Passage—3.9U5.2U5.9L Engines
for transmission shift control. I t is used on 4-speed
electronic transmissions only. The throttle position sensor (TPS), idle air control
(IAC) motor and manifold absolute pressure sensor
(MAP) are attached to the throttle body. The acceler-

ator pedal cable, speed control cable and transmis VACUUM
sion control cable (when equipped) are connected to FITTING
the throttle arm.
A (factory adjusted) set screw Is used to mechani
cally limit the position of the throttle body throttle
speed using this screw. All Idle speed functions are
controlled by the PCM.
THROTTLE BODY—8.0L ENGINE

Filtered air from the air cleaner enters the intake
manifold through the side mounted throttle body
(Fig. 82). Fuel does not enter the intake manifold
through the throttle body. Fuel Is sprayed into the
manifold by the fuel injectors. The throttle body Is
mounted on the Intake manifold, i t contains an air
control passage (Fig. 33) controlled by an idle air con
trol (IAC) motor. The air control passage is used to
supply air for Idle conditions. A throttle valve (plate)
PASSAGE CONTROL (IAC)
is used to supply air for above idle conditions. MOTOR
INTAKE MANIFOLD VIEW FROM BOTTOM J9414.48

UPPER HALF
Fig. 33 Air Controi Passage—8.0L Engine
DIAGNOSIS AND T E S T I N G
VISUAL INSPECTION—3.9L/5.2L/5.9L ENGINES

A visual inspection for loose, disconnected or incor
rectly routed wires and hoses should be made. This
should be done before attempting to diagnose or ser
vice the fuel injection system. A visual check will
help spot these faults and save unnecessary test and
diagnostic time. A thorough visual inspection will
include the following checks:
(1) Verify that the three 32-way electrical connec
tors are fully inserted into the connector of the pow
ertrain control module (PCM) (Fig. 34).
NUTS (4) J9414-57
Fig. 82 Throttie Body—8.0L Engine

The throttle position sensor (TPS) and idle air con
trol (IAC) motor are attached to the throttle body.
The accelerator pedal cable, speed control cable and
transmission control cable (when equipped) are con
nected to the throttle arm.
controlled by the PCM. Fig. 34 Powertrain Controi Module (PCM)
14 - 44 FUEL SYSTEM

(2) Inspect the battery cable connections. Be sure and inspect spark events for fouled or damaged spark
that they are clean and tight. plugs or cables.
(3) Inspect fuel pump relay and air conditioning (6) Verify that generator output wire, generator
compressor clutch relay (if equipped). Inspect the connector and ground wire are firmly connected to
ASD relay * connections. Inspect starter motor relay the generator.
connections. Inspect relays for signs of physical dam (7) Inspect the system body grounds for loose or
age and corrosion. The relays are located In the dirty connections. Refer to Group 8, Wiring for
Power Distribution Center (PDC) (Fig. 35). Refer to ground locations.
label on PDC cover for relay location. (8) Verify positive crankcase ventilation (PCV) valve
operation. Refer to Group 25, Emission Control System
for additional information. Verify PCV valve hose is
firmly connected to PCV valve and manifold (Fig. 37).

(4) Inspect ignition coil connections. Verify that coil
secondary cable is firmly connected to coil (Fig. 36).
Fig. 37 PCV Valve Hose Connections—3.9U5.2U
5.9L Engines—Typical
(9) Inspect fuel tube quick-connect fitting-to-fuel
rail connections.
(10) Verify that hose connections to all ports of
vacuum fittings on intake manifold are tight and not
leaking.
(11) Inspect accelerator cable, transmission throt
tle cable (if equipped) and cruise control cable con
nections (if equipped). Check their connections to the
throttle arm of throttle body for any binding or
restrictions.
(12) I f equipped with vacuum brake booster, verify
that vacuum booster hose is firmly connected to fit
ting on intake manifold. Also check connection to
brake vacuum booster.
(13) Inspect the air cleaner inlet and air cleaner
Fig. 36 Ignition Coil—3.9U5.2U5.9L Engines—Typical
element for dirt or restrictions.
(5) Verify that distributor cap is correctly attached (14) Inspect radiator grille area, radiator fins and
to distributor. Be sure that spark plug cables are air conditioning condenser for restrictions.
firmly connected to the distributor cap and the spark (15) Verify that the intake manifold air tempera
plugs are in their correct firing order. Be sure that ture sensor wire connector is firmly connected to har
coil cable is firmly connected to distributor cap and ness connector (Fig. 38) or (Fig. 39).
coil. Be sure that camshaft position sensor wire con (16) Verify that MAP sensor electrical connector is
nector (at the distributor) is firmly connected to har firmly connected to MAP sensor (Fig. 40). Also verify
ness connector. Inspect spark plug condition. Refer to that rubber L-shaped fitting from MAP sensor to the
Group 8D, Ignition. Connect vehicle to an oscilloscope throttle body is firmly connected (Fig. 41).
Eft FUEL SYSTEM 14 - 45
Fig. 38 Air Temperature Sensor—3.91 (V-6) Engine

Fig. 41 Rubber L-Shaped Fitting—MAP Sensor-to-
Throttle Body-3.9U5.2U5.9L Engines
(17) Verify that fuel injector wire harness connec
tors are firmly connected to injectors in the correct
order. Each harness connector is numerically tagged
with the Injector number (INJ 1, INJ 2 etc.) of its
corresponding fuel injector and cylinder number.
(18) Verify harness connectors are firmly con
nected to idle air control (IAC) motor, throttle posi
tion sensor (TPS) and manifold absolute pressure
(MAP) sensor (Fig. 40).
(19) Verify that wire harness connector is firmly
connected to the engine coolant temperature sensor
(Fig. 42).
Fig. 39 Air Temperature Sensor—5.2L/5.9L (V-8) Engines
Fig. 42 Engine Coolant Temperature Sensor—3.9U

(21) On 3.9L/5.2L/5.9L LDC engines, verify that
both the upstream and downstream oxygen sensor
wire connectors are firmly connected to the sensors.
Inspect sensors and connectors for damage (Fig. 43).
Fig. 40 Sensor and IAC Motor Location—Typical
(¥-8 Shown)

DOWN STREAM , UP STREAM SENSOR
OXYGEN OXYGEN ELECTRICAL
SENSOR SENSOR CONNECTOR
80570e21
Fig. 43 Upstream/Downstream Oxygen

Sensors—3.9U5.2U5.9L LDC Engines
(22) On 5.9L HDC engines, verify that both the
left and right oxygen sensor wire connectors are
firmly connected to the sensors. Inspect sensors and J9414-60
connectors for damage (Fig. 44). Fig. 45 Vehicle Speed Sensor—Typical
transmission) for damage to timing ring on drive
plate/flywheel.
(30) Verify that battery cable and solenoid feed
wire connections to the starter solenoid are tight and
clean. Inspect for chaffed wires or wires rubbing up
against other components.
USUAL INSPECTION—8 J L ENGINE

A visual inspection for loose, disconnected or incor
rectly routed wires and hoses should be made. This
should be done before attempting to diagnose or service
the fuel injection system. A visual check will help spot
these faults and save unnecessary test and diagnostic
time. A thorough visual inspection will include the follow
ing checks:
(1) Verify that the three 32-way electrical connec
Fig. 44 Left/Right Oxygen Sensors—5.9L HDC Engines
tors are fully inserted into the connector of the pow
(23) Inspect for pinched or leaking fuel tubes. ertrain control module (PCM) (Fig. 46).
Inspect for pinched, cracked or leaking fuel hoses.
(24) Inspect for exhaust system restrictions such as
pinched exhaust pipes, collapsed muffler or plugged cat
alytic convertor.
(25) I f equipped with automatic transmission, ver
ify that electrical harness is firmly connected to park/
neutral switch. Refer to Automatic Transmission
section of Group 21.
(26) Verify that the electrical harness connector is
firmly connected to the vehicle speed sensor (Fig. 45).
(27) Verify that fuel pump/gauge sender unit wire
connector is firmly connected to harness connector.
(28) Inspect fuel hoses at fuel pump/gauge sender
unit for cracks or leaks.
(29) Inspect transmission torque convertor housing
(automatic transmission) or clutch housing (manual
BR FUEL SYSTEM 14-47

(2) Inspect the battery cable connections. Be sure (6) Verify that generator output wire, generator
that they are clean and tight. connector and ground wire are firmly connected to
(3) Inspect fuel pump relay and air conditioning the generator.
compressor clutch relay (if equipped). Inspect the (7) Inspect the system body grounds for loose or
ASD relay connections. Inspect starter motor relay dirty connections. Refer to Group 8, Wiring for
connections. Inspect relays for signs of physical dam ground locations.
age and corrosion. The relays are located i n the (8) Verify crankcase ventilation (CCV) operation.
Power Distribution Center (PDC) (Fig. 47). Refer to Refer to Group 25, Emission Control System for addi
label on PDC cover for relay location. tional information.
(9) Inspect fuel tube quick-connect fitting-to-fuel
POWER
DISTRIBUTION rail connections.
CENTER (10) Verify that hose connections to all ports of
(PDC) vacuum fittings on intake manifold are tight and not
leaking.
(11) Inspect accelerator cable, transmission throt
tle cable (if equipped) and cruise control cable con
nections (if equipped). Check their connections to the
throttle arm of throttle body for any binding or
restrictions.
(12) I f equipped with vacuum brake booster, verify
that vacuum booster hose is firmly connected to fit
ting on intake manifold. Also check connection to
brake vacuum booster.
(13) Inspect the air cleaner inlet and air cleaner
J9414-10
element for dirt or restrictions.
(14) Inspect radiator grille area, radiator fins and
Fig. 47 Power Distribution Center (PDC) air conditioning condenser for restrictions.
(4) Inspect ignition coil pack primary connections. (15) Verify that the intake manifold air tempera
Verify that secondary cables are firmly connected to ture sensor wire connector is firmly connected to har
coils (Fig. 48). ness connector (Fig. 49).
II
INTAKE MANIFOLD
ENGINE
-CYLINDER^
1
NUMBER J948D-10
Fig. 49 Air Temperature Sensor—8.0L Engine

Fig. 48 Ignition Coil Pack—8.0L Engine
(16) Verify that MAP sensor electrical connector is
(5) Be sure that spark plug cables are firmly con
firmly connected to MAP sensor (Fig. 50).
nected and the spark plugs are in their correct firing
(17) Verify that fuel injector wire harness connec
order. Be sure that camshaft position sensor wire
tors are firmly connected to injectors in the correct
connector is firmly connected to harness connector.
order. Each harness connector is numerically tagged
Inspect spark plug condition. Refer to Group 8D,
with the injector number (INJ 1, INJ 2 etc.) of its
Ignition. Connect vehicle to an oscilloscope and
corresponding fuel injector and cylinder number.
inspect spark events for fouled or damaged spark
plugs or cables.
14-48 FUEL SYSTEM ~~ _ _ _ BR
Fig. 50 Map Sensor —8.0L Engine Fig. 52 Left/Right Oxygen Sensors

(18) Verify harness connectors are firmly con
nected to Idle air control (IAC) motor and throttle POST CATALYST PRE-CATALYST
OXYGEN . OXYGEN
position sensor (TPS).
SENSOR = K SENSOR
(19) Verify that wire harness connector is firmly con
nected to the engine coolant temperature sensor (Fig. 51).
805dd850
Fig. 53 Pre-Catalyst/Post Catalyst Oxygen Sensors

neutral switch. Refer to Automatic Transmission
section of Group 21.
(26) Verify that the electrical harness connector is
firmly connected to the vehicle speed sensor (Fig. 54).
Fig. 51 Engine Coolant Temperature Sensor—-8.0L Engine (27) Verify that fuel pump/gauge sender unit wire
(20) Raise and support the vehicle. connector is firmly connected to harness connector.
(21) On all 8.0L engines (HDC or MDC), verify (28) Inspect fuel hoses at fuel pump/gauge sender
that the left and right oxygen sensor wire connectors unit for cracks or leaks.
are firmly connected to the sensors. Inspect sensors (29) Inspect transmission torque convertor housing
and connectors for damage (Fig. 52). (automatic transmission) or clutch housing (manual
(22) On 8.0L MDC engine, verify that the pre-cat transmission) for damage to timing ring on drive
alyst and post catalyst oxygen sensor wire connectors plate/flywheel.
are firmly connected to the sensors. Inspect sensors (30) Verify that battery cable and solenoid feed
and connectors for damage (Fig. 53). wire connections to the starter solenoid are tight and
(23) Inspect for pinched or leaking fuel tubes. clean. Inspect for chaffed wires or wires rubbing up
Inspect for pinched, cracked or leaking fuel hoses. against other components.
(24) Inspect for exhaust system restrictions such
as pinched exhaust pipes, collapsed muffler or ASD AND FUEL P U i P RELAYS
plugged catalytic convertor. The following operations/tests apply to these
(25) I f equipped with automatic transmission, ver relays only: Automatic Shutdown (ASD) and Fuel
ify that electrical harness is firmly connected to park/ Pump. For operations/tests on all other relays, refer to
the appropriate section of this service manual.
SENSOR
ELECTRICAL
CONNECTOR

• Terminal number 30 is connected to battery volt
age and can be switched or B+ (hot) at all times.
• The center terminal number 87A is connected (a
J9414-60
circuit is formed) to terminal 30 in the de-energized
Fig. 54 Vehicie Speed Sensor—Typical (normally OFF) position.
These relays are located in the Power Distribution • Terminal number 87 is connected (a circuit is
Center (PDC) (Fig. 55). Refer to label on PDC cover formed) to terminal 30 in the energized (ON) posi
for relay location. tion. Terminal number 87 then supplies battery volt
The relay terminal numbers from (Fig. 56) can be age to the component being operated.
found on the bottom of the relay. • Terminal number 86 is connected to a switched
(+) power source.
BOTTOM VIEW RELAY

OF RELAY CONNECTOR
DIAGNOSIS A N D TESTING ( C o n t i n u e d )
• Terminal number 85 is grounded by the power-
train control module (PCM).
WESTING
(1) Remove relay before testing.
(2) Using an ohmmeter, perform a resistance test
between terminals 85 and 86. Resistance value
(ohms) should be 75 ± 5 ohms for resistor equipped
relays.
(3) Connect the ohmmeter between terminals num
ber 87A and 30. Continuity should be present at this
time.
(4) Connect the ohmmeter between terminals num
ber 87 and 30. Continuity should not be present at
this time.
(5) Use a set of jumper wires (16 gauge or small
er). Connect one jumper wire between terminal num
ber 85 (on the relay) to the ground side (-) of a 12
Volt power source.
(6) Attach the other jumper wire to the positive
side (+) of a 12V power source. Do not connect this
jumper wire to relay at this time.
Fig. 57 Manifold Absolute Pressure (MAP) Sensor—
CAUTION: Do not allow the ohmmeter to contact 3.9L/5.2L/5.9L Engines
terminals 85 or 86 during these tests. Damage to
ohmmeter may result.
(7) Attach the other jumper wire (12V +) to termi

nal number 86. This will activate the relay. Continu
ity should now be present between terminals number
87 and 30. Continuity should not be present between
terminals number 87A and 30.
(8) Disconnect jumper wires from relay and 12 Volt
power source.
(9) I f continuity or resistance tests did not pass,
replace relay. I f tests passed, refer to Group 8W, Wir
ing Diagrams for (fuel system) relay wiring schemat
ics and for additional circuit information.

T E S T — 3 J L / I . 2 L / 5 J L ENGINES
To perform a complete test of MAP sensor (Fig. 57) Fig. 58 Rubber L-Shaped Fitting—MAP Sensor-to-
and its circuitry, refer to DRB scan tool and appro
Throttle Body—3.9L/5.2L/5.9L Engines
priate Powertrain Diagnostics Procedures manual. To
test the MAP sensor only, refer to the following: age should drop to 1.5-to-2.1 volts with a hot, neutral
(1) Inspect the rubber L-shaped fitting from the idle speed condition.
MAP sensor to the throttle body (Fig. 58). Repair as (3) Test powertrain control module (PCM) cavity
necessary. A-27 for the same voltage described above to verify
the wire harness condition. Repair as necessary.
CAUTION: When testing the MAP sensor, be sure (4) Test MAP sensor supply voltage at sensor con
that the harness wires are not damaged by the test nector between terminals A and C (Fig. 59) with the
meter probes. ignition ON. The voltage should be approximately 5
volts (±0.5V). Five volts (±0.5V) should also be at
(2) Test the MAP sensor output voltage at the cavity A-17 of the PCM wire harness connector.
MAP sensor connector between terminals A and B Repair or replace the wire harness as necessary.
(Fig. 59). With the ignition switch ON and the engine
OFF, output voltage should be 4-to-5 volts. The volt-
(Fig. 61). With the ignition switch ON and the engine
OFF, output voltage should be 4-to-5 volts. The volt
A = GROUND age should drop to 1.5-to-2.1 volts with a hot, neutral
B = OUTPUT VOLTAGE SIGNAL idle speed condition.
C = 5-VOLT SUPPLY
MAP
I SENSOR
C B A
8056d9f7
Fig. 59 MAP Sensor Connector Terminals—3.9U

5.2U5.9L Engines
(5) Test the MAP sensor ground circuit at sensor
connector terminal—A (Fig. 59) and PCM connector CAVITY FUNCTION
A-4. Repair the wire harness i f necessary. 1 5-Volt Supply
Refer to Group 8W, Wiring Diagrams for cavity 2 Sensor Ground
3 Map Sensor Signal
locations.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR 805dd851
TEST—8.0L ENGINE
To perform a complete test of the MAP sensor (Fig. Fig. 61 MAP Sensor Connector Terminals—8.0L
60) and its circuitry, refer to DRB scan tool and Engine
appropriate Powertrain Diagnostics Procedures man (2) Test powertrain control module (PCM) cavity
ual. To test the MAP sensor only, refer to the follow A-27 for the same voltage described above to verify
ing: the wire harness condition. Repair as necessary.
(3) Test MAP sensor supply voltage at sensor con
nector between terminals 1 and 2 (Fig. 61) with the
ignition ON. The voltage should be approximately 5
volts (±0.5V). Five volts (±0.5V) should also be at
cavity A-17 of the PCM wire harness connector.
Repair or replace the wire harness as necessary.
(4) Test the MAP sensor ground circuit at sensor
connector terminal—2 (Fig. 61) and PCM connector
A-4. Repair the wire harness i f necessary.
Refer to Group 8W, Wiring Diagrams for cavity
locations.
HEATED OXYGEN (02S) SENSORS—3.9L/5.2L/

5.9L LCD ENGINES
To perform a complete test of the 02S sensors and
their circuitry, refer to the DRB scan tool and appro
Fig. 60 Manifold Absolute Pressure (MAP) Sensor— priate Powertrain Diagnostics Procedures manual. To
8.0L Engine test the 02S sensors only, refer to the following:
The upstream 02S sensor is located on the inlet
CAUTION: When testing the MAP sensor, be sure end of the catalytic converter (Fig. 62).
that the harness wires are not damaged by the test The downstream 0 2 S sensor is located on the out
meter probes. let end of the catalytic converter (Fig. 62).
Each 02S heating element can be tested with an
(1) Test the MAP sensor output voltage at the
ohmmeter as follows:
MAP sensor connector between terminals 1 and 3
DOWN STREAM UP STREAM of the sensor connector. Resistance should be
OXYGEN OXYGEN• between 5 and 7 ohms. Replace the sensor i f the
SENSOR SENSOR ohmmeter displays an infinity (open) reading.
HEATED OXYGEN (02S) SENSORS—8.OL

HDC/MDC ENGINES
To perform a complete test of the 02S sensors and
their circuitry, refer to the DRB scan tool and appro
priate Powertrain Diagnostics Procedures manual. To
test the 02S sensors only, refer to the following:
A total of 4 oxygen sensors (left, right, pre-catalyst
and post catalyst) are used with the 8.0L engine
when equipped with the Medium Duty Emission
Cycle (MDC) engine package.
Only 2 oxygen sensors (left and right) are used
80570e21 with the 8.0L engine when equipped with the Heavy
Fig. 62 Upstream/Downstream Oxygen Sensor Duty Emission Cycle (HDC) engine.
Location—3.9U5.2U5.9L LDC Engines The pre-catalyst 02S sensor is located on the inlet
Disconnect the 02S sensor connector. Connect the end of the catalytic converter (Fig. 64).
ohmmeter test leads across the white wire terminals The post catalyst 02S sensor is located on the out
of the sensor connector. Resistance should be let end of the catalytic converter (Fig. 64).
between 5 and 7 ohms. Replace the sensor If the The left and right sensors are located on the left
ohmmeter displays an infinity (open) reading. and right exhaust downpipes (Fig. 65).

HEATED 0IY0EN (02S) SENSORS—5.9L HDC
OXYGEN OXYGEN
ENSINE
To perform a complete test of the dual (left and
right) 02S sensors and their circuitry, refer to the
DRB scan tool and appropriate Powertrain Diagnos
tics Procedures manual. To test the 02S sensors only,
refer to the following:
The left and right 02S sensors are located on the
left and right exhaust downpipes (Fig. 63).
805dd850
Fig. 64 Pre-Catalyst/Post Catalyst Oxygen Sensor

Locations—HDC/MDC Engines
Each 0 2 S heating element can be tested with an
Disconnect the 0 2 S sensor connector. Connect the
ohmmeter test leads across the white wire terminals
of the sensor connector. Resistance should be
between 5 and 7 ohms. Replace the sensor i f the
ohmmeter displays an infinity (open) reading.
CAMSHAFT AND CRANKSHAFT POSITION

Fig. 68 Left/Right Oxygen Sensor Location—5.9L
HDC Engine SENSORS
Refer to Group 8D, Ignition System for informa
Each 02S heating element can be tested with an tion.
Disconnect the 02S sensor connector. Connect the
ohmmeter test leads across the white wire terminals
tance (as measured across the sensor terminals)
should be less than 1340 ohms with the engine
warm. Refer to the Coolant Temperature sensor/In
take Air Temperature sensor resistance chart.
Replace the sensor i f it is not within the range of
resistance specified in the chart.
TEMPERATURE RESISTANCE (OHMS)
C F mm MAR
-40 291,490 381,710

-20 -4 85,850 108,390
-10 14 49,250 61,430
0 32 29,330 35,990
10 50 17,990 21,810
20 68 11,370 13,610
Fig. 65 left/Right Oxygen Sensor Locations—HDC/ 25 77 9,120 10,880
MDC Engines 30 86 7,370 8,750
40 104 4,900 5,750
ENGINE COOLANT TEMPERATURE SENSOR—3.9L/ 50 122 3,330 3,880
5.2L/5.9L ENGINES 60 140 2,310 2,670
70 158 1,630 1,870
To perform a complete test of the engine coolant 80 176 1,170 1,340
temperature sensor and its circuitry, refer to DRB 90 194 860 970
scan tool and appropriate Powertrain Diagnostics 100 212 640 720
Procedures manual. To test the sensor only, refer to 110 230 480 540
the following: 120 248 370 410
(1) Disconnect wire harness connector from coolant
J928D-4
temperature sensor (Fig. 66).
(2) Engines w i t h a i r conditioning: When SENSOR RESISTANCE (OHMS)—COOLANT
removing the connector from sensor, do not pull TEMPERATURE SENSOR/INTAKE AIR
directly on wiring harness. Fabricate an L-shaped TEMPERATURE SENSOR
hook tool from a coat hanger (approximately eight
inches long). Place the hook part of tool under the (4) Test continuity of the wire harness between the
connector for removal. The connector is snapped onto PCM wire harness connector and the coolant sensor
the sensor. I t is not equipped with a lock type tab. connector terminals. Refer to Group 8, Wiring for ter
minal/cavity locations. Repair the wire harness i f an
open circuit is indicated.
(5) After tests are completed, connect electrical
connector to sensor. The sensor connector is symmet
rical (not indexed). I t can be installed to the sensor
in either direction.
ENGINE COOLANT TEMPERATURE SENSOR—8.0L

ENGINE
To perform a complete test of the engine coolant
temperature sensor and its circuitry, refer to DRB
scan tool and appropriate Powertrain Diagnostics
Procedures manual. To test the sensor only, refer to
the following:
(1) Disconnect wire harness connector from coolant
temperature sensor (Fig. 67).
(2) Test the resistance of the sensor with a high
Fig. 66 Engine Coolant Temperature Sensor—3.9U input impedance (digital) volt-ohmmeter. The resis
5.2U5.9L Engines tance (as measured across the sensor terminals)
(3) Test the resistance of the sensor with a high should be less than 1340 ohms with the engine
input impedance (digital) volt-ohmmeter. The resis warm. Refer to the Coolant Temperature sensor/In-
14 - 54 FUEL SYSTEM ™- — - ~
Fig. 67 Engine Coolant Temperature Sensor—8.0L Fig. 68 Intake Manifold Air Temperature Sensor—
Engine 3.9L V-6 Engines!
take Air Temperature sensor resistance chart.
Replace the sensor i f i t Is not within the range of
resistance specified i n the chart.
(3) Test continuity of the wire harness between the
PCM wire harness connector and the coolant sensor
connector terminals. Refer to Group 8, Wiring for ter
minal/cavity locations. Repair the wire harness i f an
open circuit Is indicated.
(4) After tests are completed, connect electrical
connector to sensor.
IDLE AIR CONTROL (IAC) M O T O R — 3 J L / 5 J L / 5 J L

ENGINES
To perform a complete test of the IAC motor and
its circuitry, refer to DRB scan tool and appropriate
Powertrain Diagnostics Procedures manual.
IDLE AIR CONTROL (IAC) MOTOR—8.0L ENGINE 5.2U5.9L V-8 Engines!
To perform a complete test of the IAC motor and sensor resistance chart. Replace the sensor i f i t is not
its circuitry, refer to DRB scan tool and appropriate within the range of resistance specified in the chart.
Powertrain Diagnostics Procedures manual. (3) Test the resistance of the wire harness. Do this
between the PCM wire harness connector A-15 and
INTAKE MANIFOLD AIR TEMPERATURE SENSOR™ the sensor connector terminal. Also check between
3.9L/5.2L/5.9L ENGINES PCM connector A-4 to the sensor connector terminal.
To perform a complete test of the intake manifold Repair the wire harness as necessary i f the resis
air temperature sensor and its circuitry, refer to DRB tance is greater than 1 ohm.
tester and appropriate Powertrain Diagnostics Proce
dures manual. To test the sensor only, refer to the INTAKE MANIFOLD AIR TEMPERATURE SENSOR—
following: 8.0L ENGINE
(1) Disconnect the wire harness connector from the To perform a complete test of the intake manifold
intake manifold air temperature sensor (Fig. 68) or air temperature sensor and its circuitry, refer to DRB
(Fig. 69). tester and appropriate Powertrain Diagnostics Proce
(2) Test the resistance of the sensor with an input dures manual. To test the sensor only, refer to the
impedance (digital) volt-ohmmeter. The resistance (as following:
measured across the sensor terminals) should be less (1) Disconnect the wire harness connector from the
than 1340 ohms with the engine warm. Refer to the intake manifold air temperature sensor (Fig. 70).
Coolant Temperature sensor/Intake Air Temperature
Fig. 70 intake Manifold Air Temperature Sensor—

8.0L Engine
(2) Test the resistance of the sensor with an Input
impedance (digital) volt-ohmmeter. The resistance (as
measured across the sensor terminals) should be less
than 1840 ohms with the engine warm. Refer to the
Fig. 71 TPS—3.9U5.2U5.9L Engines
Coolant Temperature sensor/Intake Air Temperature
sensor resistance chart. Replace the sensor If i t is not THROTTLE POSITION SENSOR (TPS)—8.0L
within the range of resistance specified i n the chart. ENGINE
(3) Test the resistance of the wire harness. Do this To perform a complete test of the TPS and its cir
between the PCM wire harness connector A-15 and cuitry, refer to the DRB scan tool and appropriate
the sensor connector terminal. Also check between Powertrain Diagnostics Procedures manual. To test
PCM connector A-4 to the sensor connector terminal. the TPS only, refer to the following:
Repair the wire harness as necessary i f the resis The TPS can be tested with a digital voltmeter.
tance is greater than 1 ohm. The center terminal of the TPS is the output termi
nal (Fig. 72).
To perform a complete test of the sensor and its
circuitry, refer to DRB scan tool and appropriate
THROTTLE POSITION SENSOR (TPS)—3.9L/5.2L/

5 J L ENGINES
To perform a complete test of the TPS and its cir
cuitry, refer to the DRB scan tool and appropriate
Powertrain Diagnostics Procedures manual. To test
the TPS only, refer to the following:
The TPS can be tested with a digital voltmeter.
The center terminal of the TPS is the output termi
nal (Fig. 71).
With the ignition key in the ON position, check the
TPS output voltage at the center terminal wire of the
connector. Check this at idle (throttle plate closed)
Fig. 72 TPS—8.0L Engine
and at wide open throttle (WOT). At idle, TPS output
voltage should must be greater than 200 millivolts. With the ignition key in the ON position, check the
At wide open throttle, TPS output voltage must be TPS output voltage at the center terminal wire of the
less than 4.8 volts. The output voltage should connector. Check this at idle (throttle plate closed)
increase gradually as the throttle plate is slowly and at wide open throttle (WOT). At idle, TPS output
opened from idle to WOT. voltage should must be greater than 200 millivolts.
At wide open throttle, TPS output voltage must be
14 - 56 FUEL SYSTE.,. - — — BR
less than 4.8 volts. The output voltage should (4) Install the 0.185 inch orifice tool (number 6714)
increase gradually as the throttle plate is slowly into the disconnected vacuum line in place of the
opened from idle to WOT. PCV valve (Fig. 74).
(5) Disconnect the idle purge vacuum line from fit
THROTTLE BODY MINIMUM AIR FLOW CHECK ting at throttle body. This vacuum line is located on
PROCEDURE—3.9L/5.2L/5.9L ENGINES the front of throttle body next to the MAP sensor
The following test procedure has been developed to (Fig. 75). Cap the fitting at throttle body after vac
check throttle body calibrations for correct idle condi uum line has been removed.
tions. The procedure should be used to diagnose the
^ FRONT O F E N G I N E
throttle body for conditions that may cause idle prob
lems. This procedure should be used only after
normal diagnostic procedures have failed to
produce results that indicate a t h r o t t l e body
related problem. Be sure to check for proper
operation of the idle air control motor before
performing this test.
A special fixed orifice tool (number 6714) (Fig. 73)
must be used for the following test.
SPECIAL TOOL 6714
ll L )
H • — *C
THROTTLE
J9414-7
BODY J9414-6
Fig. 73 Fixed Orifice Tool Fig. 75 Idle Purge Line

(1) Start the engine and bring to operating tem (6) Connect the DRB scan tool to the 16-way data
perature. Be sure all accessories are off before per link connector. This connector is located under the
forming this test. instrument panel to the left of the steering column.
(2) Shut off the engine and remove the air cleaner Refer to the appropriate Powertrain Diagnostic Pro
element housing. cedures service manual for DRB operation.
(3) Disconnect the vacuum line at the PCV valve (7) Start the engine.
(Fig. 74). (8) Using the DRB scan tool, scroll through the
menus as follows: select—System, select—Engine,
select—Fuel and Ignition, select—Actuator Tests,
select—Engine rpm and select—Minimum Air Flow.
(9) The DRB scan tool will count down to stabilize
the idle rpm and display the minimum air flow idle
rpm. The idle rpm should be between 500 and 900
rpm. I f the idle speed is outside of these specifica
tions, replace the throttle body. Refer to Throttle
Body in the Component Removal/Installation section
of this group.
(10) Disconnect the DRB scan tool from the vehi
cle.
(11) Remove cap from idle purge fitting at throttle
body and install vacuum line.
(12) Remove orifice tool and connect vacuum line
to PCV valve.
Fig. 74 install Orifice Tool (13) Install air cleaner element housing.
— _ — — ~ — FUEL SYSTEM 14-57
AUTOMATIC SHUTDOWN (ASP) RELAY

The ASD relay is located in the Power Distribution
Center (PDC) (Fig. 76). Refer to label on PDC cover
for relay location. Check terminal connections at
PDC and relay for damage/corrosion before installa
tion. Repair as necessary.
Fig. 77 Sensor Eiectricai Connectors—3.9U5.2U5.9L
ENGINES—Typical
Fig. 76 Power Distribution Center (PDC) THROTTLE BODY
FUEL P U i P BELAY
The fuel pump relay Is located in the Power Distri
bution Center (PDC) (Fig. 76). Refer to label on PDC
cover for relay location. Check terminal connections
at relay and PDC for damage/corrosion before instal
lation. Repair as necessary.
THROTTLE BODY—3.9L/5.2L/5.9L ENGINES

controlled by the powertrain control module (PCM).
REMOVAL
(2) Disconnect throttle body electrical connectors
at MAP sensor, IAC motor and TPS (Fig. 77).
(3) Remove vacuum line at throttle body.
(4) Remove all control cables from throttle body
(lever) arm. Refer to the Accelerator Pedal and Throt Fig. 78 Throttle Body Mounting Bolts—3.9U5.2U
tle Cable section of this group for additional informa 6.91 ENGINES—Typical
tion.
INSTALLATION
(5) Remove four throttle body mounting bolts (Fig.
(1) Clean the mating surfaces of the throttle body
78).
and the intake manifold.
(6) Remove throttle body from intake manifold.
(2) Install new throttle body-to-intake manifold
(7) Discard old throttle body-to-intake manifold
gasket.
gasket.
(3) Install throttle body to intake manifold.
(4) Install four mounting bolts. Tighten bolts to 23

(5) Install control cables. (5) Install control cables.
(6) Install vacuum line to throttle body. (6) Install electrical connectors.
(7) Install electrical connectors. (7) Install air cleaner housing to throttle body.
(8) Install air cleaner. (8) Install 4 air cleaner housing mounting nuts.
Tighten nuts to 11 N-m (96 in. lbs.) torque.
THROTTLE BODY—8.0L ENGINE (9) Install air cleaner housing cover.
A (factory adjusted) set screw Is used to mechani
cally limit the position of the throttle body throttle THROTTLE POSITION SENSOR (TPS)—3.9L/5.2L/
plate. Never attempt to adjust the engine idle 5.9L ENOINES
controlled by the powertrain control module (PCM). REMOVAL
The TPS is located on the side of the throttle body.
REMOVAL (1) Remove air intake tube at throttle body.
(1) Remove the air cleaner cover. (2) Disconnect TPS electrical connector.
(2) Remove the 4 air cleaner housing mounting (3) Remove two TPS mounting bolts (Fig. 80).
nuts and remove housing from throttle body.
(3) Disconnect throttle body electrical connectors THROTTLE
at the IAC motor and TPS.
(4) Remove all control cables from throttle body
(lever) arm. Refer to the Accelerator Pedal and Throttle
Cable section of this group for additional information.
(5) Remove four throttle body mounting nuts (Fig. 79).
INTAKE MANIFOLD
UPPER HALF
Fig. 80 TPS Mounting Bo its—3.9U5.2U5.9L Engines

(4) Remove TPS from throttle body.
INSTALLATION
The throttle shaft end of the throttle body slides
into a socket in the TPS (Fig. 81). The TPS must be
installed so that i t can be rotated a few degrees. I f
the sensor will not rotate, install the sensor with the
throttle shaft on the other side of the socket tangs.
The TPS will be under slight tension when rotated.
(1) Install the TPS and two retaining bolts.
NUTS (4) J9414-57 (2) Tighten bolts to 7 N-m (60 in. lbs.) torque.
Fig. 79 Throttie Body Mounting Nuts—8.0L Engine (3) Manually operate the throttle control lever by
hand to check for any binding of the TPS.
(6) Remove throttle body from intake manifold. (4) Connect TPS electrical connector to TPS.
(7) Discard old throttle body-to-intake manifold (5) Install air intake tube.
gasket.
THROTTLE POSITION SENSOR (TPS)—8.0L
INSTALLATION
(1) Clean the mating surfaces of the throttle body ENGINE
and the intake manifold.
REMOVAL
(2) Install new throttle body-to-intake manifold gasket.
The TPS is located on the side of the throttle body
(3) Install throttle body to intake manifold.
(Fig. 82).
(4) Install four mounting nuts. Tighten nuts to 22
(1) Remove air intake tube at air cleaner housing.
(2) Remove the air cleaner cover.
THROTTLE THROTTLE THROTTLE THROTTLE
BODY POSITION BODY POSITION
THROTTLE SOCKET LOCATING THROTTLE SOCKET LOCATING

SHAFT TANGS J9214-52 SHAFT TANGS J9214-52
Fig. 81 Installation—3.9L/5.2L/5.9L Engines—Typical Fig. 83 Installation—Typical Mounting

(3) Remove the 4 air cleaner housing mounting (3) Manually operate the throttle control lever by
nuts and remove housing from throttle body. hand to check for any binding of the TPS.
(4) Disconnect TPS electrical connector. (4) Connect TPS electrical connector to TPS.
(5) Remove two TPS mounting bolts (Fig. 82). (5) Install air cleaner housing to throttle body.
(6) Install 4 air cleaner housing mounting nuts.
IDLE AIR Tighten nuts to 11 N-m (96 in. lbs.) torque.
CONTROL MOTOR
(7) Install air cleaner housing cover.
(8) Install air intake tube to cover.
IDLE AIR CONTROL (IAC) MOTOR—3.9L/5.2L/5.9L

ENGINES
The IAC motor is located on the back of the throt
tle body (Fig. 84).
REMOWAL
(2) Disconnect electrical connector from IAC motor.
(3) Remove two mounting bolts (screws) (Fig. 84).
(4) Remove IAC motor from throttle body.
THROTTLE
POSITION
SENSOR J9414-3
Fig. 82 TPS Mounting Bolts—8.01 Engine

(6) Remove TPS from throttle body.
INSTALLATION
The throttle shaft end of the throttle body slides
into a socket in the TPS (Fig. 83). The TPS must be
installed so that it can be rotated a few degrees. I f
the sensor will not rotate, install the sensor with the
J9214-23
throttle shaft on the other side of the socket tangs.
The TPS will be under slight tension when rotated. Fig. 84 Mounting Bolts (Screws)—IAC Motor—3.9U
(1) Install the TPS and two retaining bolts. 5.2U5.9L Engines
(2) Tighten bolts to 7 N-m (60 In. lbs.).torque.
14 - 80 FUEL SYSTEM
mm
INSTALLATION
(1) Install IAC motor to throttle body.
(2) Install and tighten two mounting bolts (screws)
(3) Install electrical connector.
IDLE AIR CONTROL (IAC) MOTOR—8.0L ENGINE

The IAC motor is located on the back of the throt
tle body (Fig. 85).
REMOWAL
(2) Remove the 4 air cleaner housing mounting
nuts and remove housing from throttle body.
(3) Disconnect electrical connector from IAC motor.
(4) Remove two mounting bolts (screw).
Fig. 86 MAP Sensor L-Shaped Rubber Fitting—8.9U
5.2U5.9L Engines
(2) Remove throttle body. Refer to Throttle Body
removal in this section.
(3) Remove two MAP sensor mounting bolts
(screws) (Fig. 86).
(4) While removing MAP sensor, slide the vacuum
rubber L-shaped fitting (Fig. 86) from the throttle
body.
(5) Remove rubber L-shaped fitting from MAP sen
sor.
INSTALLATION
(1) Install rubber L-shaped fitting to MAP sensor.
(2) Position sensor to throttle body while guiding
rubber fitting over throttle body vacuum nipple.
Fig. 85 IAC Motor—8.0L Engine (3) Install MAP sensor mounting bolts (screws).
Tighten screws to 3 N-m (25 in. lbs.) torque.
(5) Remove IAC motor from throttle body. (4) Install throttle body. Refer to Throttle Body
installation in this section.
INSTALLATION
(1) Install IAC motor to throttle body.
(2) Install and tighten two mounting bolts (screws)
(3) Install electrical connector. SENSOR—8.0L ENGINE
(4) Install air cleaner housing to throttle body. The MAP sensor is mounted into the right upper
(5) Install 4 air cleaner housing mounting nuts. side of the intake manifold (Fig. 87). A rubber gasket
Tighten nuts to 11 N-m (96 in. lbs.) torque. is used to seal the sensor to the intake manifold. The
(6) Install air cleaner housing cover. rubber gasket is part of the sensor and is not ser
viced separately.
REMOVAL
SENSOR—3JL/IJL/iJL ENIINES (1) Remove the electrical connector at the sensor.
The MAP sensor is located on the front of the (2) Clean the area around the sensor before
throttle body. An L-shaped rubber fitting is used to removal.
connect the MAP sensor to throttle body (Fig. 86). (3) Remove the two sensor mounting bolts.
(4) Remove the sensor from the intake manifold.
REMOVAL
The throttle body must be removed from the intake
manifold for MAP sensor removal.
Fig. 87 MAP Sensor Location—8.0L ¥-10 Engine-

Typical
INSTALLATION
(1) Check the condition of the sensor seal. Clean
the sensor and lubricate the rubber gasket with clean
engine oil. Fig. 88 E¥AP Canister Purge Solenoid—3.9U5.2U
(2) Clean the sensor opening in the intake mani 5.9L Engines—Typical
fold.
(3) Install the sensor into the intake manifold. (2) Remove the 4 air cleaner housing mounting
(4) Install sensor mounting bolts. Tighten bolts to nuts and remove housing from throttle body.
2 N-m (20 in. lbs.) torque.
(5) Install the electrical connector to sensor.
DUTY CYCLE EVAP CANISTER PURGE

S O L E N O I D — 3 J L / I J L / I J L ENGINES
REMOVAL
(1) Remove air cleaner housing.
(2) Disconnect wiring connector at solenoid (Fig.
88).
(3) Disconnect vacuum harness at solenoid (Fig.
88).
(4) Remove solenoid and its support bracket from
intake manifold.
(5) Remove EVAP canister purge solenoid from
engine.
INSTALLATION
(1) Install EVAP canister purge solenoid and its
mounting bracket to intake manifold.
(2) Connect vacuum harness and wiring connector. J9425-16
(3) Install air cleaner housing.
Fig. 89 E¥AP Canister Purge Solenoid—8.0L Engine
DUTY CYCLE EWAP CANISTER PURGE
(3) Disconnect vacuum harness at solenoid.
SOLENOID—8 J L ENGINE
(4) Disconnect wiring connector at solenoid.
The solenoid is located at the rear of the throttle
(5) Lift solenoid and rubber grommet from mount
body (Fig. 89). ing bracket.
REMOVAL
14-62 FUEL S Y S T E M BR
INSTALLATION OXYGEN S E N S O R S — 3 . 9 L / 5 . 2 L / 5 . 9 L LDC/HDC
(1) Install solenoid to mounting bracket. ENGINES
(2) Install wiring connector to solenoid. On 3.9L/5.2L/5.9L LDC engines, the upstream and
(3) Install vacuum harness to solenoid. downstream 02S sensors are located at the inlet and
(4) Install air cleaner housing to throttle body. outlet ends of the catalytic converter (Fig. 91).
(5) Install 4 air cleaner housing mounting nuts. On 5.9L HDC engines, the left and right 02S sen
Tighten nuts to 11 N-m (96 in. lbs.) torque. sors are located on the left and right exhaust down-
(6) Install air cleaner housing cover. pipes (Fig. 92).
POWERTRAIN CONTROL M O i U L E (PCM) DOWN STREAM UP STREAM
The PCM Is located in the engine compartment OXYGEN OXYGEN
(Fig. 90). SENSOR SENSOR
80570e21
Fig. 91 Oxygen Sensor Location—3.9U5.2U5.9L

LDC ENGINES
Fig. 90 PCM Location and Mounting

REMOVAL
(1) Disconnect the negative battery cable at bat
tery.
(2) Carefully unplug the three 32-way connectors
from PCM.
(3) Remove three PCM mounting bolts and remove
PCM from vehicle.
INSTALLATION
(1) Install PCM and mounting bolts to vehicle.
(2) Tighten bolts to 4 N-m (35 in. lbs.).
(3) Check pin connectors in the PCM and the three
32-way connectors for corrosion or damage. Repair
as necessary.
(4) Install three 32-way connectors. Fig. 92 Oxygen Sensor Location—5.9L HDC
(5) Install battery cable. ENGINES
REMOVAL
CRANKSHAFT POSITION SENSOR
Refer to Group 8D, Ignition System for removal/In WARNING: THE EXHAUST MANIFOLD, EXHAUST
stallation procedures. PIPES AND CATALYTIC CONVERTER B E C O M E
VERY HOT DURING ENGINE OPERATION. ALLOW
CAMSHAFT POSITION SENSOR ENGINE TO COOL B E F O R E REMOVING OXYGEN
For removal/installation procedures, refer to Group SENSOR.
8D, Ignition System. See Camshaft Position Sensor.
(2) Disconnect the wire connector from the 02S
sensor.

CAUTION: When disconnecting the sensor electri
cal connector, do not pull directly on wire going
into sensor.
(3) Remove the 02S sensor. Snap-On oxygen sen

sor wrench (number YA 8875) may be used for
removal and installation.
INSTALLATION
Threads of new oxygen sensors are factory coated
with anti-seize compound to aid i n removal. DO
NOT add any additional anti-seize compound to
the threads of a new oxygen sensor.
(1) Install the 02S sensor. Tighten to 30 N-m (22
ft. lbs.) torque.
(2) Connect the 02S sensor wire connector.
Fig. 94 Left/Right Oxygen Sensor Location—All 8.0L
OXYGEN SENSORS—8.0L ENGINES Engines
On 8.0L MDC engines, the pre-catalyst and post CAUTION: When disconnecting the sensor electri
catalyst 02S sensors are located at the Inlet and out cal connector, do not pull directly on wire going
let ends of the catalytic converter (Fig. 93). into sensor.
On 8.0L MDC or HDC engines, the left and right
02S sensors are located on the left and right exhaust (3) Remove the 02S sensor. Snap-On oxygen sen
downpipes (Fig. 94). sor wrench (number YA 8875) may be used for
removal and installation.
OXYGEN OXYGEN INSTALLATION
Threads of new oxygen sensors are factory coated
with anti-seize compound to aid in removal. DO
NOT add any additional anti-seize compound to
the threads of a new oxygen sensor.
(1) Install the 02S sensor. Tighten to 30 N-m (22
ft. lbs.) torque.
(2) Connect the 02S sensor wire connector.
AIR CLEANER HOUSING/AIR CLEANER ELEMENT

(FILTER)—3.9L/5.2L/5.9L ENGINES
For air cleaner element required maintenance
805dd850
schedules (listed in time or mileage intervals), refer
Fig. 93 Pre-Catalyst/Post Catalyst Oxygen Sensor to Group 0, Lubrication and Maintenance.
Location—8.0L MDC Engines Only
REMOVAL
CAUTION: Do not attempt to remove the air
WARNING: THE EXHAUST MANIFOLD, EXHAUST cleaner element (filter) from the housing by remov
PIPES AND CATALYTIC CONVERTER BECOME ing the top cover only. To prevent damage to the air
VERY HOT DURING ENGINE OPERATION. ALLOW cleaner housing, the entire air cleaner housing
ENGINE TO COOL BEFORE REMOVING OXYGEN assembly must be removed from the engine for air
SENSOR. cleaner element replacement.
(1) Raise and support the vehicle. (1) Remove the air inlet tube (Fig. 95) at the side
(2) Disconnect the wire connector from the 02S of the air cleaner housing.
sensor. (2) A band-type screw clamp secures the air
cleaner housing to the throttle body. Loosen, but do
AIR INLET (11) Position the air cleaner housing assembly to the
throttle body while guiding the rubber grommet over
the mounting stud. The lower part of the screw clamp
should be below the top lip of the throttle body.
(12) Push down on air cleaner housing at rubber
grommet to seat housing at intake manifold.
(13) Tighten throttle body-to-air cleaner housing
clamp to 4 N-m (35 In. lbs.) torque.
(14) Install the air inlet tube at air cleaner hous
ing inlet.
AIR CLEANER HOUSINI/AIR CLEANER ELEMENT

(FILTER)—8 J L ¥-11 ENGINE
For air cleaner element required maintenance
schedules (listed In time or mileage Intervals), refer
to Group 0, Lubrication and Maintenance.
A small amount of engine oil wetting the inside of
the air cleaner housing is normal. When servicing,
wipe out the oil from the air cleaner housing.
REmowAL/msmLLATiom
(1) Loosen the clamp (Fig. 96) and remove the air
inlet tube (Fig. 97) at the front of the air cleaner
housing cover.
CLAMP ADJUSTABLE PLIERS
Fig. 95 Air Cleaner Housing—3.9U5.2U5.9L Engines

not remove, this screw clamp (Fig. 95). Note the
clamp positioning tabs on the air cleaner housing.
(3) A l l Engines: Disconnect the breather hose at
the rear of air cleaner housing.
(4) 5.9L V-8 HDC Engine Only: Disconnect the air
pump hose at the air cleaner housing.
(5) The bottom/front of the air cleaner housing is
equipped with a rubber grommet (Fig. 95). A mount
ing stud is attached to the intake manifold (Fig. 95)
and Is used to position the air cleaner housing into J9314-136
this grommet. Lift the assembly from the throttle
body while slipping the assembly from the mounting Fig. 96 Clamp Removal—8.0L Engine
stud (Fig. 95). (2) The air cleaner housing and air cleaner element
(6) Check condition of gasket at throttle body and cover are equipped with spring clips to seal the cover to
replace as necessary. housing (Fig. 97). Unlatch the clips from the air cleaner
(7) The housing cover is equipped with three (3) cover and remove cover from air cleaner housing.
spring clips (Fig. 95) and is hinged at the rear with (3) Remove the air cleaner element from air
plastic tabs. Unlatch the clips from the top of air cleaner cover.
cleaner housing and tilt the housing cover up and (4) Before installing a new air cleaner element,
rearward for cover removal. clean Inside of air cleaner housing.
(8) Remove the air cleaner element from air (5) I f housing removal is necessary, remove the 4
cleaner housing. housing-to-throttle body nuts.
(9) Before installing a new air cleaner element, (6) After installing housing, tighten 4 nuts to 11
clean inside of air cleaner housing. N-m (96 in. lbs.) torque.
(10) Position air cleaner cover to tabs on rear of (7) Position air cleaner element (filter) Into air
air cleaner housing. Latch the three spring clips to cleaner cover. Latch the spring clips to seal cover to
seal cover to housing. housing.
REMOVAL A N D INSTALLATION fContinued)

HOUSING (1) Partially drain cooling system. Refer to Group
7, Cooling.
(3) Disconnect electrical connector from sensor
(Fig. 99).
(4) Engines with air conditioning: When remov
ing the connector from sensor, do not pull directly on
wiring harness. Fabricate an L-shaped hook tool from a
coat hanger (approximately eight inches long). Place the
hook part of tool under the connector for removal. The
connector is snapped onto the sensor. It is not equipped
with a lock type tab.
(5) Remove sensor from intake manifold.
Fig, 97 Air Cleaner Housing—8.0L ¥-10 Engine

(8) Install the air inlet tube at air cleaner housing
inlet.
(9) Install and tighten clamp at air inlet tube (Fig.
98).
CLAMP ADJUSTABLE PLIERS
Fig. 99 Engine Coolant Temperature Sensor—3.9U

INSTALLATION
(1) Install sensor.
(2) Tighten to 11 N-m (8 ft. lbs.) torque.
(3) Connect electrical connector to sensor. The sen
sor connector is symmetrical (not indexed). It can be
installed to the sensor in either direction.
(5) Replace any lost engine coolant. Refer to Group
7, Cooling System.
ENGINE COOLANT TEMPERATURE SENSOR—8.0L

ENGINE
Fig. 98 Clamp Installation—8.0L Engine
REMOVAL
ENGINE COOLANT TEMPERATURE SENSOR—3 J L /
5.2L/5.9L ENGINES WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
REMOVAL MUST BE PARTIALLY DRAINED BEFORE REMOV
ING THE COOLANT TEMPERATURE SENSOR.
WARNING: HOT, PRESSURIZED COOLANT CAN
REFER TO GROUP 7 , COOLING.
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOVING (1) Partially drain cooling system. Refer to Group
THE COOLANT TEMPERATURE SENSOR. REFER TO 7, Cooling.
GROUP 7, COOLING. (2) Disconnect electrical connector from sensor
(Fig. 100).
REHOWAL AND INSTALLATION (Continued)
Fig. 102 Air Temperature Sensor—5.2L/5.9L (V-8)

Fig. 100 Engine Coolant Temperature Sensor—8.0L Engines
Engine
INSTALLATION
INSTALLATION (1) Install sensor to intake manifold. Tighten to 28
(1) Install sensor. N-m (20 ft. lbs.) torque.
(2) Tighten to 11 N-m (8 ft. lbs.) torque. (2) Install electrical connector.
( 3 ) Connect electrical connector to sensor. (3) Install air cleaner.
(4) Replace any lost engine coolant. Refer to Group
7, Cooling System. INTAKE MANIFOLD AIR TEMPERATURE SENSOR—
8.0L ENGINE
INTAKE MANIFOLD AIR TEMPERATURE SENSOR—
The intake manifold air temperature sensor is
3.9L/5.2L/5.9L ENGINES located in the side of the intake manifold near the
The intake manifold air temperature sensor is front of throttle body (Fig. 103).
located in the front/side of the intake manifold (Fig.
101) or (Fig. 102). REMOVAL
(1) Disconnect electrical connector at sensor.
REMOVAL (2) Remove sensor from intake manifold.
(2) Disconnect electrical connector at sensor (Fig.
101) or (Fig. 102).
Fig. 103 Air Temperature Sensor—8.0L Engine

INSTALLATION
(1) Install sensor to intake manifold. Tighten to 28
Fig. 101 Air Temperature Sensor—3.9L (V-6) Engine N-m (20 ft. lbs.) torque.
(2) Install electrical connector.

VEHICLE SPEED SENSOR (4) Remove the sensor (pull straight out) from the
The vehicle speed sensor Is located on the speed speedometer pinion gear adapter (Fig. 105). Do not
ometer pinion gear adapter (Fig. 104). The pinion remove the gear adapter from the transmission.
gear adapter is located on the extension housing of
INSTALLATION
the transmission (drivers side).
(1) Clean the inside of speedometer pinion gear
SENSOR
adapter before installing speed sensor.
ELECTRICAL (2) Install sensor into speedometer gear adapter
CONNECTOR and install mounting bolt. Before tightening bolt,
verify speed sensor is fully seated (mounted
flush) to speedometer pinion gear adapter.
(3) Tighten sensor mounting bolt to 2.2 N-m (20 in.
lbs.) torque.
(4) ' Connect electrical connector to sensor.
SPECIFICATIONS
VECi LABEL SPECIFICATIONS

If anything differs between the specifications found
on the Vehicle Emission Control Information (VECI)
tions on VECI label. The VECI label Is located in the
engine compartment.
J9414-60
Fig. 104 Vehicle Speed Sensor Location—Typical DESCRIPTION TORQUE

Air Cleaner Housing Mount.
SPEEDOMETER Nuts—8.0L Engine . . . . . 11 N-m (96 in. lbs.)
P I N I O N GEAR Air Cleaner Housing Metal Clamp—
3.9L/5.2L/5.9L Engines .4 N-m (35 in. lbs.)
Crankshaft Position Sensor Mounting
Bolts—All Engines 8 N-m (70 in. lbs.)
Camshaft Position Sensor Mounting—
8.0L Engine 6 N-m (50 in. lbs.)
Engine Coolant Temperature
Sensor—All Engines 11 N-m (96 in. lbs.)
Fuel Tank Mounting Nuts 41 N-m (30 ft. lbs.)
Fuel Hose Clamps . .1 N-m (10 in. lbs.)
IAC Motor-To-Throttle Body Bolts .7 N-m (60 in. lbs.)
Intake Manifold Air Temp. Sensor—
All Engines 28 N-m (20 ft. lbs.)
MAP Sensor Mounting Screws—
3.9L/5.2L/5.9L Engines 3 N-m (25 in. lbs.)
MAP Sensor Mounting Screws—
8.0L Engine . 2 N-m (20 in. lbs.)
Oxygen Sensor—All Engines . . . .30 N-m (22 ft. lbs.)
SPEED Powertrain Control Module Mounting
SENSOR J9314-188 Screws 4 N-m (35 in. lbs.)
Fig. 105 Sensor Removal/Installation Throttle Body Mounting Bolts—
3.9L/5.2L/5.9L Engines . 23 N-m (200 in. lbs.)
REMOVAL Throttle Body Mounting Bolts—
(1) Raise and support vehicle. 8.0L Engine 22 N-m (192 in. lbs.)
(2) Disconnect the electrical connector from the sensor. Throttle Position Sensor Mounting
(3) Remove the sensor mounting bolt (Fig. 105). Screws—All Engines 7 N-m (60 in. lbs.)
Vehicle Speed Sensor Mounting
Bolt . . . . . .2.2 N-m (20 in. lbs.)
Spanner Wrench—6856
Test Kit, Fuel Pressure—5069
Adapters, Fuel Pressure Test—654% 6539, 6631 or Fuel Line Removal Tool—6782
6923
02S (Oxygen Sensor) Remover/Installer—G-4907

FUEL D E L I V E R Y S Y S T E M - D I E S E L ENGINE
INDEX
page page
DESCRIPTION AND OPERATION FUEL TRANSFER PUMP PRESSURE/CAPACITY

FUEL DELIVERY SYSTEM 69 TEST 77
FUEL DRAIN MANIFOLD 76 HIGH-PRESSURE FUEL LINE LEAK T E S T 84
FUEL FILTER/WATER SEPARATOR 73 IDLE S P E E D ADJUSTMENT 85
FUEL GAUGE SENDING UNIT 71 SERVICE PROCEDURES
FUEL HEATER RELAY 72 AIR BLEED PROCEDURE 85
FUEL HEATER 71 FUEL INJECTION PUMP TIMING 86
FUEL INJECTION PUMP 74 THROTTLE LINKAGE ADJUSTMENT—DIESEL
FUEL INJECTORS 74 ENGINE 92
FUEL SHUTDOWN SOLENOID RELAY 76 REMOVAL AND INSTALLATION
FUEL SHUTDOWN SOLENOID 75 ACCELERATOR PEDAL 93
FUEL SYSTEM P R E S S U R E WARNING 73 FUEL DRAIN MANIFOLD 93
FUEL TANK FILLER TUBE CAP 73 FUEL FILTERAA/ATER SEPARATOR 94
FUEL TANK MODULE 71 FUEL HEATER RELAY 97
FUEL TANK P R E S S U R E RELIEF/ROLLOVER FUEL HEATER 96
VALVE 73 FUEL INJECTION PUMP 97
FUEL TANK 73 FUEL INJECTORS 104
FUEL TRANSFER PUMP 72 FUEL SHUTDOWN SOLENOID RELAY 106
HIGH-PRESSURE FUEL LINES 73 FUEL SHUTDOWN SOLENOID 105
QUICK-CONNECT FITTINGS 73 FUEL TANK MODULE 96
DIAGNOSIS AND TESTING FUEL TANK P R E S S U R E RELIEF/ROLLOVER
AIR IN FUEL SYSTEM .. 76 VALVE 108
FUEL FILTERA/VATER SEPARATOR T E S T 79 FUEL TANK 95
FUEL HEATER RELAY T E S T 82 FUEL TRANSFER PUMP 107
FUEL HEATER T E S T 81 HIGH-PRESSURE FUEL LINES 108
FUEL INJECTION PUMP T E S T 82 THROTTLE CABLE 109
FUEL INJECTOR T E S T 82 SPECIFICATIONS
F U E L SHUTDOWN SOLENOID RELAY T E S T . . . 84 ENGINE DATA PLATE SPECIFICATIONS 110
FUEL SHUTDOWN SOLENOID T E S T 83 FUEL SYSTEM P R E S S U R E S — D I E S E L
FUEL SUPPLY RESTRICTIONS 76 ENGINES 110
FUEL TANK CAPACITY 110
TORQUE—DIESEL ENGINES 111
DESCRIPTION AMD OPERATION • Fuel tank

• Fuel tank module
FUEL DELIVERY SYSTEM • Low and high-pressure fuel supply lines
This section of the group will cover diesel fuel deliv • Low-pressure, mechanical, fuel transfer pump
ery components not controlled by the powertrain (fuel lift pump)
control module (PCM). Various components, relays • High-pressure fuel injection pump
and switches are operated by the PCM. Refer to the • Fuel heater
Fuel Injection System—Diesel Engine sections of this • Fuel heater relay
group for components that are operated by the PCM. • Fuel shutdown solenoid
• Fuel shutdown solenoid relay
NOTE: Diesel fuel delivery (except for operation of • High-pressure fuel injectors
the intake manifold air heater and manifold air ® Fuel return line
heater relays) is not directly regulated by the PCM. • Fuel filter/water separator
• In-tank fuel filter
The fuel delivery system of the 5.9L turbo-diesel • Pre-filter (in fuel heater)
engine consists of the: • Fuel drain manifold
14 - 70 FUEL SYSTEM! BR
D E S C R I P T I O N AHO O P E R A T I O N { C o n t i n u e d !
WASTEGATED TURBOCHARGER
TURBOCHARGER OIL SUPPLY
HIGH PRESSURE
FUEL TUBES
FUEL DRAIN
LINE (MANIFOLD)
FUEL INJECTORS (6)
TURBOCHARGER
WASTEGATE
RIGHT SIDE
OF ENGINE
FUEL SUPPLY INTAKE AIR INTAKE MANIFOLD

LINE (TO TEMP. SENSOR
INJECTION PUMP)
WATER TEMPERATURE
SENSOR (FOR I.P. GAUGE)
HIGH PRESSURE FUEL FILTER/

FUEL LINES WATER SEPARATOR
FUEL/WATER
SEPARATOR AND
HIGH PRESSURE DRAIN VALVE
FUEL INJECTION
PUMP
RUBBER PRIMER
BUTTON
THROTTLE POSITION
SENSOR (AUTO. FUEL TRANSFER
TRANS. ONLY) PUMP (FUEL
LIFT PUMP)
STARTER
FUEL MOTOR
SHUTDOWN
SOLENOID
OIL PRESSURE LEFT SIDE DRAIN

SENSOR OF ENGINE TUBE J9414-69
Fig. 1 Fuel System Components—Diesel Engine

BR - — FUEL SYSTEM 14-71

FUEL TANK MODULE a float, an arm, and a variable resistor (track). The
An electric fuel pump is not used i n the fuel tank track is used to send an electrical signal used for fuel
module for diesel powered engines. Fuel is supplied gauge operation.
by the fuel transfer pump and the fuel injection As the fuel level increases, the float and arm move
pump. up. This decreases the sending unit resistance, caus
The fuel tank module is installed in the top of the ing the fuel gauge on the instrument panel to read
fuel tank (Fig. 2). The fuel tank module (Fig. 2) or full. As the fuel level decreases, the float and arm
(Fig. 3) contains the following components: move down. This increases the sending unit resis
• Fuel reservoir tance, causing the fuel gauge on the instrument
• A separate in-tank fuel filter panel to read empty.
• Pressure relief/rollover valve
• Fuel gauge sending unit FUEL HEATER
• Fuel supply line connection The fuel heater is used to prevent diesel fuel from
• Fuel return line connection waxing during cold weather operation. The fuel
• Auxiliary fuel supply fitting heater is located on the left side of the engine above
The electric fuel pump, normally mounted in the the starter motor (Fig. 4).
fuel pump module on gas powered engines, is not The heater assembly is equipped with a built-in
used with diesel powered engines. sensor (thermostat) (Fig. 4) that senses fuel temper
ature. When the temperature is below 40 degrees F,
PRESSURE RELIEF/
AUX. FUEL the built-in sensor allows current to flow to the
ROLLOVER VALVE
SUPPLY FITTING built-in heater element warming the fuel. When the
temperature is above 80 degrees F, the sensor stops
PLASTIC current flow to the heater element.
LOCKNUT
FUEL FUEL TEMPERATURE SENSOR
SUPPLY
UNE
FUEL
RETURN
UNE
FRONT FUEL GAUGE
OF TANK SENDING
UNIT
ELECTRICAL
CONNECTOR
J9414-70
Fig. 2 Top View of Fuel Tank Module—Diesel

FUEL GAUGE LOCKING
FLOAT v SENDING UNIT TABS
ELECTRIC
F U E L PUMP
FUEL
TRANSFER
PUMP
ELECTRICAL
CONNECTOR
FUEL
HEATER J9414-94
Fig. 4 Fuel Heater and Temperature Sensor Location

Voltage to operate the fuel heater is supplied from
the ignition switch and through the fuel heater relay.
MOUNTING Also refer to Fuel Heater Relay.
IN-TANK
SCREWS FUEL FILTER J9414-33 The fuel heater and fuel heater relay are not con
trolled by the powertrain control module (PCM).
Fig. 3 Fuel Gauge Sending Unit—Typical The built-in heater element operates on 12 volts,
300 watts at 0 degrees F.
FUEL GAUGE SENDING UNIT The fuel heater assembly contains a pre-filter to
The fuel gauge sending unit is attached to the side prevent contaminants from entering the fuel transfer
of the fuel pump module. The sending unit consists of pump.
S E S C R i P T g & H mm O P E R A T I O N ccomtmued)
FUEL HEATER RELAY the side of the injection pump. This valve opens at
Voltage to operate the fuel heater is supplied from approximately 152 kPa (22 psi) and returns fuel to
the ignition switch through the fuel heater relay. The the fuel tank through the fuel return line.
powertrain control module (PCM) is not used to con CHECK LOW PRESSURE
trol this relay. VALVES SUPPLY UNE RUBBER
A I C
The fuel heater relay is located in the engine com PRIMER PUMP
BUTTON
partment near the brake master cylinder (Fig. 5).
FUEL SHUT-OFF
FUEL HEATER SOLENOID RELAY
RELAY
\ BRAKE MASTER
CYLINDER
/
FUEL LINE
ENGINE INLET J9414-71
CAMSHAFT
Fig. 6 Transfer Pump Operation
FUEL RETURN LINE
OVERFLOW
VALVE
J9414-31
Fig. 5 Fuel Heater Relay—Diesei

FUEL TRANSFER PUMP
The fuel transfer pump (fuel lift pump) is located
on the left-rear side of the engine cylinder block
above the starter motor (Fig. 1). This mechanically
operated pump is not controlled by the powertrain
control module (PCM).
The purpose of the fuel transfer pump is to supply
(transfer) a low-pressure fuel source of approximately
172 Kpa (25 psi) to the injection pump and fuel filter/
water separator from the fuel tank. Here, the low- FUEL INJECTION
PUMP J9414-102
pressure is raised by the fuel injection pump for
operation of the high-pressure fuel injectors. The
transfer pump is driven by an eccentric on the engine Fig. 7 Injection Pump Overflow Valve
camshaft that actuates a spring loaded piston within The transfer pump has a primer button (Fig. 8).
the pump (Fig. 6). Check valves within the pump, This rubber primer button is located on the pump
control direction of fuel flow and prevent fuel bleed- housing. The purpose of the button is to prime and
back during engine shut down. bleed air from the fuel system i f the vehicle has run
The fuel transfer pump should never be operated out of fuel. To prime the system up to the fuel injec
without the pre-filter installed. tor pump, continually press on the button (Fig. 8)
The fuel volume of the transfer pump will vary until resistance is felt. This resistance will indicate
with engine rpm, but will always provide more fuel that priming is completed and air has been removed.
than the fuel injection pump requires. Excess fuel is I f the primer button feels as i f it is not pumping,
returned to the fuel tank through an overflow valve. rotate (crank) the engine approximately 90 degrees.
The valve is located on the side of the injection pump This will position the engine camshaft lobe away
(Fig. 7) and is used to connect the fuel return line to
FUEL SYSTEM 14 - 73
BESCRiPYi©!! AMB QPBMMmM (Continued)
from the pump piston (Fig. 6 ) . Continue pumping FUEL FILTER/WATER SEPARATOR
until air is removed. The fuel filter/water separator protects the fuel
injection pump by removing water and contaminants
from the fuel. The separator filter construction allows
FUEL
TRANSFER
fuel to pass through it, but prevents moisture (water)
from doing so. Moisture collects at the bottom of the
separator filter.
The fuel filter/water separator is located on the left
side of the engine above the starter motor (Fig. 1).
Refer to the maintenance schedules in Group 0 in
this manual for the recommended fuel filter/water
separator replacement intervals.
For draining of water, refer to the Removal/Instal
lation section of this group. See Fuel Filter/Water
Separator.
FUEL SYSTEM PRESSURE WARNING
WARNING: HIGH-PRESSURE FUEL LINES

DELIVER DIESEL F U E L UNDER EXTREME P R E S
S U R E FROM THE INJECTION PUMP TO THE F U E L
PRIMER
BUTTON
INJECTORS. THIS MAY B E A S HIGH A S 120,000
KPA (17,405 PSI). U S E EXTREME CAUTION WHEN
J9414-72
INSPECTING FOR HIGH-PRESSURE F U E L L E A K S .
INSPECT FOR HIGH-PRESSURE FUEL L E A K S WITH
Fig. 8 Fuel Transfer Pump—Manual Operation
A S H E E T OF CARDBOARD. HIGH F U E L INJECTION
FUEL TANK P R E S S U R E CAN C A U S E PERSONAL INJURY IF
Refer to Fuel Tank in the Fuel Delivery System— CONTACT IS MADE WITH THE SKIN.
Gasoline section of this group for information.
FUEL TANK FILLER TUBE CAP QUICK-CONNECT FITTINGS

The loss of any fuel or vapor out of filler neck is Refer to Quick-Connect Fittings in the Fuel Deliv
prevented by the use of a pressure-vacuum fuel tank ery System—Gasoline section for information. Also
filler tube cap. Relief valves inside cap will release refer to the Fuel Tubes/Lines/Hoses and Clamps sec
only under significant pressure of 6.58 to 8.44 kPa tion.
(1.95 to 2.5 psi). The vacuum release for all gas caps
is between .97 and 2.0 kPa (.14 and .29 psi). This cap HIGH-PRESSURE FUEL LINES
must be replaced by a similar unit i f replacement is
necessary. This is in order for the system to remain CAUTION: The high-pressure fuel lines must be
effective. held securely in place in their holders. The lines
cannot contact each other or other components. Do
CAUTION: * Remove fuel tank filler tube cap before not attempt to weld high-pressure fuel lines or to
servicing any fuel system component. This is done repair lines that are damaged. Only use the recom
to help relieve tank pressure. mended lines when replacement of high-pressure
fuel line is necessary.
FUEL TANK PRESSURE RELIEF/ROLLOVER VALVE High-pressure fuel lines deliver fuel under pres
The pressure relief/rollover valve will relieve fuel sure of up to approximately 120,000 kPa (17,405 PSI)
tank pressure and prevent fuel flow through fuel from the injection pump to the fuel injectors. The
tank vent hoses during rollover. A l l vehicles pass a lines expand and contract from the high-pressure
full 360 degree rollover without fuel leakage. fuel pulses generated during the injection process. All
The pressure relief/rollover valve is mounted at the high-pressure fuel lines are of the same length and
top of fuel tank module. inside diameter. Correct high-pressure fuel line usage
On diesel powered engines, the top of the valve is and installation is critical to smooth engine opera
open to atmosphere. Refer to Group 25, Emission tion.
Control Systems for more information.
D E S C R I P T I O N AMD OPERATION (Continued)

WARNING: USE EXTREME CAUTION WHEN AIR FLOW
INSPECTING FOR HIGH-PRESSURE FUEL LEAKS. CONTROL (AFC)
INSPECT FOR HIGH-PRESSURE FUEL LEAKS WITH
A SHEET OF CARDBOARD. HIGH FUEL INJECTION
PRESSURE CAN CAUSE PERSONAL INJURY IF
CONTACT IS MADE WITH THE SKIN.
FUEL INJECTION PUMP

The fuel injection pump is a Bosch P 7 1 0 0 series in
line type (Fig. 9). The injection pump is driven by the
engine camshaft. A gear on the end of the pump shaft
meshes with the camshaft gear. The pump is timed
to the engine. Fuel injection occurs near the end of
the compression stroke for each cylinder.
DELIVERY OIL FILL PLUG

VALVES
RQV-K
AFC GOVERNOR
P7100 INLINE
FUEL INJECTION
PUMP J9414-104
Fig. 10 Injection Pump Governor and AFC

Excess fuel is returned to the fuel tank by an over
flow valve (Fig. 7) on the injection pump. This vent
opens at approximately 152 kPa (22 psi) and returns
fuel to the fuel tank through the fuel return line.
Diesel fuel and engine oil are used to cool the fuel
injection pump. A separate oil feed line from the
engine supplies engine oil to the pump. The oil
returns to the engine through an opening at the front
of pump.
A KSB (cold start) solenoid is not used.
P7100 INLINE The injection pump high idle speed is factory-
FUEL INJECTION sealed and is not adjustable. The low idle speed is
PUMP ACCESS
PLUG J9414-75 adjustable. Refer to Idle Speed Adjustment.
For injection pump timing, refer to Fuel Injection
Fig. 9 Fuel Injection Pump Pump Timing.
The RQV-K governor (Fig. 9 ) has a pump timing
feature. This will allow the pump shaft to be oriented FUEL INJECTORS
in a position corresponding to top dead center (TDC) The fuel injectors are mounted on the left side of
for the compression stroke of cylinder number one. the cylinder head (Fig. 11). The injectors are con
Indexing the governor flyweight assembly to the nected to the fuel injection pump by the high-pres
shaft during assembly establishes pump timing. sure fuel lines. A separate injector is used for each
. As engine speed increases, the internal pump pres cylinder.
sure increases. An air-fuel control (AFC) (Fig. 10) on The injectors consist of the nozzle holder, o-ring
the governor ensures that regulated fuel delivery is water seal, shims, spring, needle valve and nozzle.
matched to intake manifold pressure (turbocharger Fuel enters the injector at the fuel inlet (top of injec
boost) for emission control. tor) and is routed to the needle valve bore. When fuel
The mechanical fuel transfer pump delivers fuel pressure rises to approximately 26,252 kPa (3,822
under a low- pressure of approximately 172 Kpa (25 psi), the needle valve spring tension is overcome. The
psi) to the injection pump through the fuel filter/wa needle valve rises and fuel flows through the spray
ter separator. The injection pump then supplies high- holes in the nozzle tip into the combustion chamber.
pressure fuel of approximately 120,000 kPa (17,400 The pressure required to lift the needle valve is the
psi) to each injector in precise metered amounts at operating pressure setting. This is sometimes
the correct time. referred to as the "pop" pressure setting.
VTION f C o n t i n u e d !
HIGH FRONT OF ENGINE AIR TEMPERATURE SENSOR

PRESSURE SENSOR ELECTRICAL
FUEL LINE CONNECTOR
6)
J91l 4-74 ^
Fig. 11 Fuel Injectors—Typical

INTAKE
Fuel pressure in the injector circuit decreases after MANIFOLD F ( J E L
(UPPER H A L F ) W N SOLENOID^
injection. The injector needle valve is immediately S H U T D O
SOLENOID ELECTRICAL
closed by the needle valve spring and fuel flow into CONNECTOR
J9414-93
the combustion chamber is stopped. Exhaust gases
are prevented from entering the injector nozzle by Fig. 12 Fuel Shutdown Solenoid Location
the needle valve.
FUEL SHUTDOWN SOLENOID SHUTDOWN

RUN POSITION
POSITION
The fuel shutdown solenoid and fuel shut
down solenoid relay are not controlled by the
powertrain control module (PCM).
The fuel shutdown (shut-off) solenoid is used to
electrically shut off the diesel fuel supply to the high-
pressure fuel injection pump. The solenoid is
mounted to the side of the pump and is connected to
the pump with a lever (Fig. 12).
The solenoid controls starting and stopping of the
engine regardless of the position of the accelerator
pedal. When the ignition switch is off, the solenoid
plunger is spring loaded (down) in the shutdown posi
tion (Fig. 13) and fuel is shut off to the injection pump.
Two different coils are located within the solenoid
and a three-wire pigtail wire harness is attached to
the solenoid. FUEL
SHUTDOWN
When the ignition switch is turned to the CRANK SOLENOID
(starter engaged) position, high-amperage current J9414-80
(approximately 40 amps at 12 volts) is supplied to
one of the coils in the shutdown solenoid from the Fig. 13 Fuel Shutdown Solenoid Positions
fuel shutdown solenoid relay. This high-amperage
current allows the solenoid shaft to pull up on the Voltage to operate the solenoid is supplied from the
injection pump lever. The injection pump shutdown ignition switch and through the fuel shutdown solenoid
lever is then positioned to the run position (Fig. 13). relay. Also refer to Fuel Shutdown Solenoid Relay.
When the ignition key is released to the ON posi If the shutdown solenoid is being replaced, its
tion, a low- amperage current is supplied to the other shaft length must be adjusted. For fuel shutdown
coil i n the solenoid. This is used to hold the solenoid solenoid removal, installation and solenoid shaft
shaft i n the up position. Accelerator pedal position adjustment procedures, refer to the Component
then controls fuel lever position for fuel control at the Removal/Installation section of this group.
injection pump.
FUEL SHUTDOWN SOLENOID RELAY

Voltage to operate the fuel shutdown (shut-off)
solenoid is supplied from the ignition switch and
through the fuel shutdown solenoid relay. The Pow
ertrain Control Module (PCM) has no control over
the solenoid. The fuel shutdown solenoid relay is
located in the engine compartment near the brake
master cylinder (Fig. 14).
FUEL SHUT-OFF
FUEL HEATER SOLENOID RELAY
Fig. 15 Fuel Drain Manifold—Typical

seals. Air can also enter the fuel system between the
fuel tank and the transfer pump. Inspect the fuel
tank and fuel lines for damage that might allow air
into the system.
For air bleeding, refer to the Air Bleed Procedure.
FUEL SUPPLY RESTRICTIONS
LOW-PRESSURE LINES
Fuel supply line restrictions or a defective fuel
transfer pump can cause starting problems and pre
vent the engine from revving up. The starting prob
lems include; low power and blue or white fog like
Fig. 14 Fuel Shutdown (Shut-Off) Solenoid Location exhaust. Test all fuel supply lines for restrictions or
blockage. Flush or replace as necessary. Bleed the
FUEL DRAIN MANIFOLD fuel system of air once a fuel supply line has been
Some fuel is continually vented from the fuel injec replaced. Refer to the Air Bleed Procedure section of
tion pump to cool the pump and the fuel injectors. this group for procedures. Also refer to the Fuel
During injection, a small amount of fuel flows past Transfer Pump Pressure Test section of this group for
the injector nozzle and is not injected into the com restriction tests.
bustion chamber. This fuel drains into the fuel drain
manifold (Fig. 1 5 ) . Fuel in the drain manifold is then HIGH-PRESSURE LINES
routed back to the fuel filter/water separator. Restricted (kinked or bent) high-pressure lines can
cause starting problems, poor engine performance
and black smoke from exhaust.
D I A G N O S S S AMB TESTING
Examine all high-pressure lines for any damage.
Each radius on each high-pressure line must be
AIR IN FUEL SYSTEM
smooth and free of any bends or kinks.
Air will enter the fuel system whenever fuel supply Replace damaged, restricted or leaking high-pres
lines, separator filters, injection pump, high-pressure sure fuel lines with the correct replacement line.
lines or injectors are removed or disconnected. Air
trapped in the fuel system can result in hard start CAUTION: The high-pressure fuel lines must be
ing, a rough running engine, engine misfire, low clamped securely in place in the holders. The lines
power, excessive smoke and fuel knock. After service cannot contact each other or other components. Do
is performed, air must be bled from the system not attempt to weld high-pressure fuel lines or to
before starting the engine. repair lines that are damaged. Only use the recom
Inspect the fuel system from the fuel transfer mended lines when replacement of high-pressure
pump to the injectors for loose connections. Leaking fuel line is necessary.
fuel is an indicator of loose connections or defective
FUEL TRANSFER PUMP PRESSURE/CAPACITY OUTPUT PRESSURE TEST

TEST (1) Remove the clamp bolt retaining the fuel drain
For operation of the fuel transfer pump primer button, manifold line to the cylinder head (Fig. 17).
refer to Fuel Transfer Pump in the Fuel Delivery—Diesel
Engine section of this group.
The fuel transfer pump is located on the left side of
the engine and above the starter motor (Fig. 16).
FUEL
TRANSFER
PUMP
ELECTRICAL
CONNECTOR
FUEL
HEATER J9414-94
Fig. 16 Fuel Transfer Pump Location
J9514-68
An improperly operating fuel transfer pump can
cause low engine power and/or hard engine starting. Fig. 17 Fuel Line Fittings
Inspect the fuel supply line to the pump for restric
tions, kinks or leaks. (2) Remove the rear banjo fitting bolt at the inlet
Fuel leaking from the weep hole in the pump cas line (Fig. 17).
ing indicates a leaking pump. The transfer pump (3) Position the fuel drain manifold line (Fig. 17)
must then be replaced or rebuilt. to the rear.
Do not operate the fuel system with a fuel line or (4) Install and tighten special adapter tool 6829
component suction restriction of more than approxi into the top of the fuel inlet line (Fig. 18).
mately 100 M M Hg (4.0 inch Hg). (5) Install a 0-60 or 0-100 psi fuel pressure gauge
Low transfer pump output can be caused by a worn to adapter tool 6829 (Fig. 18).
eccentric on the engine camshaft. (6) Start engine and record fuel pressure. Mini
The maximum allowable fuel pressure drop across the mum pressure should be 172 kPa (25 psi) at rated
fuel filter/water separator is 35 kPa (5 psi). As the filter speed.
removes contaminants in the fuel, the pressure drop (7) I f fuel pressure falls below specifications, test
across the fuel filter/water separator will increase. Fre for fuel line inlet restrictions and overflow valve
quent replacement of the filter may indicate a worn operation before condemning the fuel transfer pump.
Proceed to step (a).
transfer pump. The filter/separator can be checked with a
fuel pressure gauge. For test procedures, refer to Fuel (a) Remove the rubber fuel hose and clamps
Filter/Water Separator Tests in this section of the group. located between the fuel heater and fuel transfer
Refer to Group 0, Lubrication and Maintenance at pump (Fig. 19).
the front of this manual for recommended replace (b) Install special hose adapter tool 6837
ment intervals. between the disconnected fittings on the heater
and transfer pump (Fig. 20). Install clamps to hose
tool 6837.

FUEL
FUEL FUEL
TRANSFER
PRESSURE DRAIN
PUMP
GAUGE MANIFOLD
LINE
FUEL SPECIAL HOSE

HEATER ADAPTER TOOL
6837
J9514-73
Fig. 20 Installing Hose Adapter
LINE
J9514-69
Fig. 18 installing Special Tools

(c) Connect vacuum gauge 6828 to T-fitting (Fig,
21).
(d) Start the engine and observe the vacuum
gauge. The vacuum gauge will not indicate a vac
uum until the transfer pump begins to operate at
full capacity.
FUEL T-FITTING
TRANSFER
J9514-74
Fig. 21 Installing Vacuum Gauge

(10) Install rubber fuel hose and clamps between
heater and pump.
FUEL VOLUME TEST

Fuel volume-versus-engme cranking rpm are used
for the test.
WARNING: TO PREVENT T H E ENGINE FROM

STARTING, DISCONNECT THE PIGTAIL HARNESS
FUEL RUBBER AT THE F U E L SHUTDOWN SOLENOID (Fig. 22). U S E
HEATER FUEL HOSE J9514-72
CAUTION A S RESIDUAL F U E L MAY C A U S E THE
ENGINE TO START AND RUN TEMPORARILY.
Fig. 19 Rubber Fuel Hose—Pump to Heater ATTEMPT TO START T H E ENGINE A F E W TIMES
NOTE: Under load, maximum inlet restriction must UNTIL IT QUITS B E F O R E PERFORMING T H E F U E L
not exceed approximately 100 mm Hg (4 in. Hg). VOLUME T E S T .
(8) I f the restriction is higher than the specifica (1) Connect a hand held tachometer to the engine.
tions, check for a kinked fuel line or a plugged fuel Use Cummins part number 3377462 or an equiva
tank vent. A partially clogged in-tank fuel filter can lent.
also cause excess vacuum. Repair as necessary. (2) Remove the clamp bolt retaining the fuel drain
(9) Remove vacuum gauge and adapter hose tool. manifold line to the cylinder head (Fig. 17).
BR FUEL SYSTEM 14 - 7?
FRONT OF ENGINE AIR TEMPERATURE SENSOR

(7) Place the other end of this temporary hose into
SENSOR ELECTRICAL a graduated container (Fig. 23).
CONNECTOR (8) Crank the engine for 30 seconds. Measure the
fuel volume in the container after 30 seconds of
engine cranking time. Do not crank the engine for
more than 30 seconds at a time. Starter motor
damage may result.
(9) To determine the correct fuel volume, refer to
for Fuel Volume Specification. To use the chart in
(Fig. 24), refer to the following procedure:
• Draw a straight vertical line at the measured
rpm.
• Draw a straight horizontal line at the measured
fuel volume.
• I f these two lines intersect below the flow line
(Fig. 24), this indicates a defective transfer pump or
a line restriction.
INTAKE • I f these two lines intersect above the flow line
MANIFOLD (Fig. 24), this indicates acceptable fuel flow.
(UPPER HALF) SHUTDOWN SOLENOID
SOLENOID ELECTRICAL
J9414-93 ml FLOW UNE
CONNECTOR
625
Fig. 22 Fuel Shutdown Solenoid Electrical 6 0 0
Connector 5 7 5
(3) Remove the rear banjo fitting bolt at the inlet 5 5 0

c
line (Fig. 17). O
u
5 2 5
(4) Position the fuel drain manifold line (Fig. 17) m

to 500
to the rear. o
4 7 5
CO
(5) Install and tighten special adapter tool 6836
4 5 0
into the top of the fuel inlet line (Fig. 23).
m
(6) Connect a temporary rubber fuel hose to £ 4 2 5
3
adapter 6836 (Fig. 23). 400
i 3 7 5
TEMPORARY
m
RUBBER D 3 5 0
HOSE
325
3 0 0
275
200 225 250 275 300 400
Engine Cranking Speed (RPM) j9414.no
Fig. 24 Fuel Volume Specifications
FUEL FILTER/WATER SEPARATOR TEST
A blocked or clogged fuel filter/water separator can
cause starting problems and prevent the engine from
revving up. I t can also cause, low power and blue or
white fog like exhaust.
The maximum allowable fuel pressure drop across
the fuel filter/water separator is 35 kPa (5 psi). This
can be checked with a fuel pressure gauge connected
to the inlet and outlet sides of the upper part of the
GRADUATED filter base with special fuel line adapter fittings.
J9514-75 CONTAINER
To test fuel pressure drop:
(1) Remove the clamp bolt retaining the fuel drain
Fig. 23 Performing Fuel Volume Test manifold line to the cylinder head (Fig. 25).
D I A G N O S I S A N D TESTING (Continued)
Fig. 26 Installing Special Tools
Fig. 25 Fuel Line Fittings

(2) Remove the rear banjo fitting bolt at the inlet
line (Fig. 25).
(3) Position the fuel drain manifold line (Fig. 25)
to the rear.
(4) Install and tighten special adapter tool 6829
into the top of the fuel inlet line (Fig. 26).
(5) Install a 0-60 or 0-100 psi fuel pressure gauge
to adapter tool 6829 (Fig. 26).
(6) Start engine and record fuel pressure. Mini
mum pressure should be 172 kPa (25 psi). I f not,
refer to Fuel Transfer Pump Pressure Test for more
information
(7) Remove fuel pressure gauge and adapter tool.
(8) Connect banjo fittings together at fuel inlet line
with bolt.
(9) Remove the front banjo fitting bolt at the outlet Fig. 27 Installing Special Tools
line (Fig. 25). (15) I f the instrument panel mounted water-in-fuel
(10) Install and tighten special adapter tool 6829 warning lamp is illuminated with the ignition key
into the top of the fuel outlet line (Fig. 27). ON, it indicates that excess water has collected in
(11) Install fuel pressure gauge to adapter tool the fuel filter/water separator. Excess water can be
6829 (Fig. 27). drained. Refer to Fuel Filter/Water Separator in the
(12) Start engine and record fuel pressure. Component Removal/Installation section of this group
(13) Compare the 2 pressures. I t must not exceed for water draining procedures.
35 kPa (5 psi). (16) I f excess water gathers in the filter/separator
(14) I f pressure specification has been exceeded, in a short period of time, the fuel tank must be
replace fuel filter and check for line restrictions. removed, drained and cleaned.
D I A G N O S I S &M® T E S T i ^ Q feogitiBisuecF.)
FUEL HEATER TEST FROM FUEL
The fuel heater is used to prevent diesel fuel from TANK
waxing during cold weather operation. TO FUEL

TRANSFER
NOTE: The fuel heater element, fuel heater relay PUMP
and fuel heater temperature sensor are not con FUEL
trolled by the powertrain control module (PCM). TEMPERATURE
^ SENSOR
A malfunctioning fuel heater can cause a wax
build-up in the fuel filter/water separator. Wax v MOUNTING
build-up in the filter/separator can cause engine PRE-FILTER BRACKET/
SPACER
starting problems and prevent the engine from rev
SCREEN
ving up. I t can also cause blue or white fog-like FUEL HEATER
exhaust. I f the heater is not operating in cold tem ASSEMBLY
MACHINED
peratures, the engine may not operate due to fuel HEX J9414-95
waxing.
The fuel heater is located on the left side of the Fig. 29 Fuel Heater Assembly
engine above the starter motor (Fig. 28). FUEL SHUT-OFF
FUEL TEMPERATURE SENSOR FUEL HEATER SOLENOID RELAY
RELAY j
BRAKE MASTER
CYLINDER
FUEL
TRANSFER
PUMP
ELECTRICAL
CONNECTOR
FUEL
HEATER J9414-94
Fig. 80 Fuel Heater Relay—Diesel
Fig. 28 Fuel Heater Location
The built-in heater element operates on 12 volts,
The heater assembly is equipped with a built-in 300 watts at 0 degrees F. As temperature increases,
fuel temperature sensor (thermostat) (Fig. 29) or power requirements decrease.
(Fig. 28) that senses fuel temperature. When the fuel The fuel heater assembly contains a pre-filter (Fig.
temperature is below 40 degrees F, the sensor allows 29) to prevent contaminants from entering the fuel
current to flow to the built-in heater element to transfer pump.
warm the fuel. When the fuel temperature is above A minimum of 7 volts is required to operate the
80 degrees F, the sensor stops current flow to the fuel heater. The resistance value of the heater ele
heater element (circuit is open). ment is less than 1 ohm (cold) and up to 1000 ohms
Voltage to operate the fuel heater element is sup warm.
plied from the ignition switch, through the fuel
heater relay (Fig. 30) (also refer to Fuel Heater TESWIMG
Relay), to the fuel temperature sensor and on to the (1) Remove the electrical connector at the side of
fuel heater element. «, the fuel heater (Fig. 28).
(2) Using an ohmmeter, check the resistance
across the two terminals on the side of the heater.
14 • 82 FUEL SYSTEM BR
Resistance should be approximately 1 ohm (cold) to TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN
1000 ohms (warm). BLEEDING AIR FROM THE F U E L S Y S T E M .
(3) With the electrical connector still unplugged
from the fuel heater, check the electrical operation of To determine which fuel injector is malfunctioning,
the fuel temperature sensor (Fig. 29). Proceed to next run the engine and loosen the high-pressure fuel line
step: nut at the injector (Fig. 31). Listen for a change in
(4) Using an ohmmeter, check the resistance engine speed. After testing, tighten the line nut to 30
across the two terminals in the pigtail wire harness N-m (22 ft. lbs.) torque. I f engine speed drops, the
coming from the fuel temperature sensor. The sensor injector was operating normally. I f engine speed
circuit should be open i f the fuel temperature is remains the same, the injector may be malfunction
above 80 degrees. The sensor circuit should be closed ing. Test all injectors in the same manner one at a
if the fuel temperature is below 40 degrees. time.
(5) Check for 12 volts at the disconnected temper
ature sensor connector with the ignition key ON.
Refer to Group 8W, Wiring for electrical schematics.
(6) With ignition ON, check for 12 volts at the fuel
heater relay connector. Refer to Group 8W, Wiring for
electrical schematics.
(7) Check operation of the fuel heater relay (Fig.
30). Refer to Relays—Operation/Testing in this sec
tion of the group.
FUEL HEATER RELAY TEST

The fuel heater relay is located in the engine com
To test the relay only, refer to Relays—Operation/
Testing in this section of the group.
To test the fuel heater, refer to Fuel Heater Test in
this section of the group. Fig. 31 inspecting injector Operation
FUEL INJECTOR TEST Once an injector has been found to be malfunction

A leaking fuel injector can cause fuel knock, poor ing, remove i t from the engine and test it. Refer to
performance, black smoke, poor fuel economy and the Diesel Engine—Component Removal/Installation
rough engine idle. I f the fuel injector needle valve section of this group for procedures.
does not operate properly, the engine may misfire After the injector has been removed, install i t to a
and produce low power. bench-mount injector tester (Cummins part number
A leak in the injection pump-to-injector high-pres 3376946 or equivalent) (Fig. 32). Position a container
sure fuel line can cause many of the same symptoms below the injector before testing. Refer to operating
as a malfunctioning injector. Inspect for a leak in the instructions supplied with tester for procedures.
high-pressure lines before checking for a malfunc The opening pressure or "pop" pressure should be
tioning fuel injector. approximately 26,252 kPa (3822 psi). I f the fuel
injector needle valve is opening (popping) too early or
WARNING: THE INJECTION PUMP S U P P L I E S too late, replace the injector.
HIGH-PRESSURE F U E L O F UP TO APPROXIMATELY
120,000 KPA (17,400 PSI) TO EACH INDIVIDUAL FUEL INJECTION PUMP TEST
INJECTOR THROUGH THE HIGH-PRESSURE LINES. The fuel shutdown solenoid, breakover throttle
F U E L UNDER THIS AMOUNT OF P R E S S U R E CAN lever, mounting o-ring, banjo washers and oil supply
PENETRATE THE SKIN AND C A U S E PERSONAL fittings are the only serviceable components of the
INJURY. WEAR S A F E T Y G O G G L E S AND ADEQUATE fuel injection pump. T h e injection pump i s not to
PROTECTIVE CLOTHING. AVOID CONTACT WITH be serviced or the w a r r a n t y m a y be voided. I f
F U E L SPRAY WHEN BLEEDING HIGH-PRESSURE the injection pump requires service, the com
F U E L LINES. plete assembly must be replaced.
Incorrect injection pump timing can cause poor
performance, excessive smoke and emissions and
WARNING: DO NOT B L E E D AIR FROM THE F U E L poor fuel economy.
SYSTEM O F A HOT ENGINE. DO NOT ALLOW F U E L

SENSOR ELECTRICAL
FUEL CONNECTOR
INJECTOR
TESTER
INTAKE
CONTAINER MANIFOLD F U E L
(UPPER HALF) S H U T D O W N SOLENOID '

J9514-71 SOLENOID ELECTRICAL
J9414-93
CONNECTOR
Fig. 82 Typical Fuel Injector Tester
Fig. 33 Fuel Shutdown Solenoid Location
A defective fuel injection pump or misadjusted
pump timing can cause starting problems or prevent
the engine from revving up. I t can also cause: SHUTDOWN
RUN POSITION
• Engine surge at idle POSITION
• Rough idle (warm engine)
• Low power
• Excessive fuel consumption
• Poor performance
• Low power
• Black smoke from the exhaust
• Blue or white fog like exhaust
• Incorrect idle or maximum speed
Engine power is also effected by the governor set
ting and performance. Do not attempt to adjust
the governor. I f the governor seals on the exter
n a l adjustment screw are broken, the fuel rate
may be out of adjustment. The warranty of the
injection pump and the engine may be void if
the seals have been tampered with or removed. FUEL
SHUTDOWN
FUEL SHUTDOWN SOLENOID TEST SOLENOID
J9414-80
NOTE: The fuel shutdown (shut-off) solenoid (Fig.

33) and fuel shutdown solenoid relay (Fig. 35) are Fig. 34 Fuel Shutdown Solenoid Positions
not controlled by the powertrain control module retracted into the solenoid) and the pump lever
(PCM). should be in the run position (fuel being supplied to
injection pump) (Fig. 34).
(1) With the ignition switch off, the solenoid shaft (3) Release the ignition key from the CRANK to
should be down and the injection pump lever should the ON position. The shaft should remain i n the up
be i n the shutdown position (no fuel supply to injec position and the pump lever should remain in the
tion pump) (Fig. 34). run position (fuel being supplied to injection pump)
(2) Turn the ignition switch to the CRANK (starter (Fig. 34). I f the solenoid shaft is not moving, refer to
engage) position and observe the solenoid shaft and the following:
injection pump lever. The shaft should pull up (shaft
FUEL SHUT-OFF HIGH-PRESSURE FUEL LINE LEAK TEST
FUEL HEATER SOLENOID RELAY High-pressure fuel line leaks can cause starting
problems and poor engine performance.
WARNING: DUE TO EXTREME FUEL PRESSURES

OF UP TO 120,000 kPa ( 1 7 , 4 0 0 PSI), USE EXTREME
CAUTION WHEN INSPECTING FOR HIGH-PRES
SURE FUEL LEAKS. DO NOT GET YOUR HAND
NEAR A SUSPECTED LEAK. INSPECT FOR HIGH-
PRESSURE FUEL LEAKS WITH A SHEET OF CARD
BOARD. HIGH F U E L INJECTION P R E S S U R E CAN
C A U S E PERSONAL INJURY IF CONTACT IS MADE
WITH THE SKIN.
Start the engine. Move the cardboard over the

high-pressure fuel lines and check for fuel spray onto
the cardboard (Fig. 36). I f a high-pressure line con
nection is leaking, bleed the system and tighten the
connection. Refer to the Air Bleed Procedure in this
group for procedures. Replace damaged, restricted or
leaking high-pressure fuel lines with the correct
replacement line.
Fig, 85 Fuel Shutdown Solenoid Relay Location
HIGH-PRESSURE CARDBOARD
(4) Disconnect the solenoid three-wire pigtail wire
harness from the main engine harness.
(5) I f the solenoid shaft did not move up when the
ignition switch was in the CRANK position, check for
12 volts at the three-way connector. This will be the
circuit coming from the fuel shutdown solenoid relay
Refer to Group 8W, for wire connector pin location
and circuit identification, i f 12 volts is not present at
this circuit when the key is in the CRANK position,
check the fuel shutdown solenoid relay. Refer to
Relays—Operation/Testing in this section of the
group. Also check the wiring between the relay and
the solenoid.
(6) I f the solenoid shaft moves up when the igni
tion switch is in the CRANK position, but moves
down when the key is released from the CRANK to
the ON position, check the circuit coming from the
ignition switch for 12 volts. Refer to Group 8W, for
wire connector pin location and circuit identification.
(7) I f the shutdown solenoid is being replaced, its J9414-130
shaft length must be adjusted. Refer to Fuel Shut
down Solenoid removal, installation and solenoid Fig. 36 Typical Test for Leaks with Cardboard
shaft adjustment for procedures. CAUTION: The high-pressure fuel lines must be
clamped securely in place in the holders. The lines
FUEL SHUTDOWN SOLENOID RELAY TEST cannot contact each other or other components. Do
Voltage to operate the fuel shutdown solenoid is not attempt to weld high-pressure fuel lines or to
supplied from the ignition switch and through the repair lines that are damaged. Only use the recom
fuel shutdown solenoid relay. The fuel shutdown sole mended lines when replacement of high-pressure
noid relay is located in the engine compartment near fuel line is necessary.
the brake master cylinder (Fig. 35).
To test the relay, refer to Relays—Operation/Test
ing in this section of the group.
IDLE SPEED ADJUSTMENT SERVICE PROCEDURES

The high idle stop screw is factory sealed and can
not be adjusted. Low-speed idle can be adjusted. AIR BLEED PROCEDURE
(1) Use an optical tachometer such as Snap-on No. A certain amount of air becomes trapped in the
MT139 or MTE (Cummins tool division) No. 3377462 fuel system when fuel system components are ser
to read the engine rpm. viced or replaced. Bleed the system after fuel system
(2) Bring the engine to normal operating tempera service according to the following procedures.
ture.
(3) Adjust the low idle speed at the low idle speed WARNING: DO NOT BLEED AIR FROM THE FUEL
screw. The screw and locknut are located at the rear SYSTEM OF A HOT ENGINE. DO NOT ALLOW FUEL
of the fuel injection pump (Fig. 37). TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN
BLEEDING AIR FROM THE FUEL SYSTEM.
LEVER STOP
MANUAL BLEEDING
Some air enters the fuel system when the filters or
injection pump supply line are changed. This small
amount of air is vented automatically from the injec
tion pump through the fuel drain manifold. This is i f
the filter was changed according to instructions.
The system will have to be bleed manually if:
• The fuel filter is not filled before installation
• The fuel injection pump is replaced
• High-pressure fuel line connections are loosened
or lines replaced
• Initial engine start-up or start-up after an
extended period of no engine operation.
(1) Loosen the low-pressure bleed bolt (Fig. 39).
FUEL
LOW IDLE DRAIN
ADJUSTING MANIFOLD
SCREW BOLT
FACTORY HIGH IDLE LOCKNUT
J9414-103
SEAL STOP SCREW
Fig. 37 Low idle Speed Screw

(4) Loosen the idle screw lock nut (Fig. 37). Adjust
idle screw to obtain specified rpm (Fig. 38).
(5) Tighten the locknut after adjustment.
LOW I D L E S P E E D H I G H IDLE S P E E D
With automatic transmission... Do not attempt to adjust

high idle speed. High idle
V50-800 RPM with transmission speed adjustment screw
drive and air conditioning on.
in is factory sealed. Breaking
seal will void injection pump
With manual transmission... warranty.
V80 RPM with transmission in

neutral and air conditioning on.
* With engine at normal operating temperature. Refer to text

for idle adjustment procedures.
r
J9414-66
HOUSING
Fig. 38 Idle Speeds—Diesel Engine
FUEL FILTER/
WATER SEPARATOR J9414-86
14 - 81 FUEL SYSTEM mm
(2) Operate the rubber push-button primer on the WEAR SAFETY GOGGLES AND ADEQUATE PRO
fuel transfer pump (Fig. 40). Do this until the fuel TECTIVE CLOTHING AND AVOID CONTACT WITH
exiting the low-pressure bleed bolt is free of air. FUEL SPRAY WHEN BLEEDING HIGH- PRESSURE
FUEL LINES-
FUEL
TRANSFER WARNING: DO NOT BLEED AIR FROM THE FUEL
PUMP
SYSTEM OF A HOT ENGINE. DO NOT ALLOW FUEL
TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN
BLEEDING AIR FROM THE FUEL SYSTEM.
Bleed air from one injector at time.

(1) Loosen the high-pressure fuel line fitting at the
injector (Fig. 41).
RUBBER
PRIMER
BUTTON
J9414-72
Fig. 40 Fuel Transfer Pump—Manual Operation

(3) Tighten low-pressure bleed screw to 8 N-m (6
ft. lbs.) torque.
FUEL INJECTION PUMP BLEEDING Fig. 41 Bleeding High-Pressure Fuel Lines

WARNING: THE ENGINE HAY START WHEN (2) Crank the engine until all air is bled from the
CRANKING TO B L E E D AIR FROM THE INJECTION line. Do not operate the starter motor for longer
PUMP. P L A C E THE TRANSMISSION IN NEUTRAL than 30 seconds. Wait t w o minutes between
OR PARK AND S E T PARKING B R A K E B E F O R E cranking intervals.
ENGAGING THE STARTER MOTOR. (3) Start the engine and bleed one injector at a
time until the engine runs smoothly.
(4) Tighten fuel line(s) at injector(s) to 30 N-m (22
CAUTION: Do not engage the starter motor for ft. lbs.) torque.
more than 30 seconds at a time. Allow two minutes
between cranking intervals. FUEL INJECTION PUMP TIMING
(1) Thoroughly clean the engine and fuel system
(1) Perform the previous procedure: Manual Bleed before attempting to remove any components. Pay
ing. special attention to the top of the fuel injection
(2) Crank the engine for 30 seconds at a time to pump. Use compressed air * to remove any water
allow air trapped in the injection pump to vent out remaining on the fuel pump after the cleaning pro
the drain manifold. Observe the previous WARNING cess.
and CAUTION.
CAUTION: DO NOT ALLOW ANY DIRT, DEBRIS, OR
HIGH-PRESSURE FUEL LINE BLEEDING PAINT CHIPS TO ENTER THE FUEL SYSTEM WHILE
IT IS OPEN. IF FOREIGN MATERIAL OF ANY TYPE
WARNING: THE FUEL INJECTION PUMP S U P P L I E S
IS ALLOWED INTO THE PUMP, LINES OR INJEC
HIGH-PRESSURE F U E L OF A S HIGH AS 120,000
TORS DURING THIS PROCESS ST COULD RESULT
KPA (17,405 PSI) TO EACH INDIVIDUAL INJECTOR
IN AN INJECTION PUMP OR FUEL INJECTOR MAL
THROUGH THE HIGH-PRESSURE LINES. F U E L
FUNCTION.
UNDER THIS AMOUNT OF P R E S S U R E CAN PENE
TRATE THE SKIN AND C A U S E PERSONAL INJURY.
SERVICE P R O C E D U R E S {Continued)
NOTE: Locate top dead center (TDC) on cylinder MACHINED HOLE
#1.
(2) Remove the rubber access plug located in the

rear flange of the engine on the exhaust manifold
side. (Fig. 42).
Fig. 42 Rotating Engine With Barring Tool Fig. 43 Back of Camshaft Gear
NOTE: Removing the #1 cylinder valve cover and
first barring (rotating) the engine clockwise until
both intake and exhaust valves are closed will
speed up locating engine TDC as described later in
step 4 .
(3) Insert the barring tool number 7471B through

the access hole and into the flywheel housing (Fig.
42).
(4) While holding tension on ' the timing pin
(toward front of engine), slowly rotate the engine
counterclockwise with the barring tool. Hold a slight
rearward (pushing) pressure on the barring tool and
continue to rotate the tool counterclockwise until the
timing pin drops into the machined hole in the back
of the camshaft gear. When the barring tool is
rotated counterclockwise, the vibration damper
should be rotating clockwise as viewed from
front. When the pin aligns to the gear (Fig. 43), and
the intake and exhaust valves are closed at the #1
cylinder, the engine is at the TDC position (compres
sion stroke) at cylinder number 1. Place a paint mark
on the dampener to indicate TDC. Remove the pin. Fig. 44 Timing Pin and Location
This will prevent damage when barring (rotat
ing) the engine in later steps. CAUTION: DO NOT BEND THE FUEL LINE. BEND
ING THE LINE WILL CAUSE LINE OR INJECTOR
NOTE: The pin is located above the power steering FAILURE.
pump, below and to the inside of the fuel injection
pump, on the rear of the cam gear housing (Fig. (6) With the engine at TDC, loosen but do not
44). remove, the front (#1) delivery valve holder using
special socket #6840 (Fig. 46). Remove the socket
(5) Remove #1 fuel injection line from the fuel from the valve holder prior to removing the holder
pump (Fig. 45). from the injection pump.
SERVICE P7.0emmmmS (Continued)
and any shims from slipping out of the holder. Place
these parts (Fig. 47) as an assembly on a clean sur
face.
(8) Using a magnet, remove the two piece delivery
valve assembly from the pump (Fig. 4 8 ) . Place these
parts on a clean surface.
J9514-77
Fic 45 Number 11njection Line
There is an external o-ring on the holder to help
prevent debris from getting into the pump. This may
create a slight resistance as the holder is unscrewed.
J9514-80
Fig. 48 Delivery Waive Assembly

(9) Using a pick, remove the metal delivery valve
washer (Fig. 4 9 ) from the top of the pumping ele
ment. Be careful not to scratch the top of the plung
er/barrel assembly during this process. Discard the
used delivery valve washer. A new washer will be
used during reassembly.
Fig, 46 Delivery Waive Holder Removal
71
J9514-81
Fig. 49 Delivery Waive Washer

(10) Install the dial indicator adaptor tool # 6 8 4 2
(Fig. 50) in place of the #1 delivery valve holder and

tighten finger tight.
(11) Loosen the set screw on the dial indicator
adaptor (Fig. 50). Install the dial indicator #6859 and
dial indicator tip #6843 into the adapter. Position the
J9514-79 dial indicator to read between 7.0 and 9.0 mm and
Fig. 47 Delivery Waive Holder tighten the set screw (Fig. 50). The dial indicator is
capable of measuring from 0-20.00 mm lift. The small
(7) Remove the delivery valve holder by carefully
inner dial is marked in increments of 1 mm. The
tipping the holder outboard with one hand while
large outer dial is marked in increments of 0.01 mm.
using the other hand to hold the spring, fill piece,
One revolution of the outer dial is equal to 1 mm.
( 1 3 ) Using the engine barring tool #7471B, rotate
the engine in the direction opposite normal direction
of engine rotation (counterclockwise from front of
engine) 1/4 turn or until you see the dial indicator
reading stop dropping. This is the inner base circle of
the injection pump cam. Zero the indicator and note
the reading on the small inner dial (Fig. 5 1 ) .
(a) Rotate the engine clockwise slowly to TDC.
(b) Note the pump lift setting on the dial indica
tor (Fig. 5 1 ) .
(c) Note the "Timing-TDC" specification (in
degrees) stamped into the engine data plate. The
engine data plate is located on the left side of the
timing gear cover (Fig. 5 2 ) .
J9514-82 (d) Compare these specifications to the Fuel
Injection Pump Plunger Lift chart (Fig. 5 3 ) .
Fig. 50 installing Special Adapter Tool
(e) I f specifications match, a fuel timing adjust
The inner dial only indicates 0 - 1 0 mm, but will ment will not be necessary. Proceed to step 2 7 .
rotate twice as the indicator goes through the full (f) I f the specifications do not match, a fuel tim
range, ing adjustment will be necessary. Proceed to next
( 1 2 ) Be sure the timing pin is disengaged step.
before rotating the engine to avoid damage to
the timing pin. FUEL I N J E C T I O N P U M P P L U N G E R LIFT-
TOTAL LIFT
4 9 STATE AUTOMATIC TRANSMISSION
TDC
OF 5.5 M M Degrees before Pump plunger lift
TO 5.9 M M top dead center (TDC) setting (mm)
12.0 4.1
12.5 4.2
13.0 4.3
13.5 4.4
14.0 4.5
F U E L I N J E C T I O N P U M P P L U N G E R LIFT-
49 S T A T E MANUAL T R A N S M I S S I O N
Degrees before Pump plunger lift
top dead center (TDC) setting (mm)
11.5 4.7
12.0 4.8
12.5 4.9
13.0 5.0
13.5 5.1
Fig. 51 Setting Dial indicator
F U E L INJECTION PUMP P L U N G E R LIFT-
ALL CALIFORNIA - EGR EQUIPPED
Degrees before Pump plunger lift
top dead center (TDC) setting (mm)
11.5 4.0
12.0 4.1
12.5 4.2
13.0 4.3
13.5 4.4
TIMING
GEAR Fig. 53 Fuel Injection Pump Plunger Lift
COVER
Adjusting Timing:
(14) Remove the oil filler tube * (Fig. 54) and
adapter elbow from the front of the timing gear hous
ing.
(15) Loosen the injection pump shaft nut (use the
Fig. 52 Engine Data Plate barring tool to keep the engine from rotating). Before
14 - 90 FUEL S Y S T E M ^ — BR
BEARING
THRUST
WASHERS
J9514-85
Fig. 56 Bearing/Thrust Washer Tools

Fig. 54 Oii Filter Tube
(17) Slowly rotate the engine clockwise until
removing pump nut or washer, place a magnet to the
reaching the required lift setting on the dial indica
end of the injection pump shaft (Fig. 55). This will
tor. Refer to Fuel Injection Pump Plunger Lift chart
prevent the nut or washer from falling into the tim
(Fig. 53). The injection pump should rotate with the
ing gear cover which will require engine disassembly
engine since the injection pump gear is still locked to
for recovery.
the injection pump shaft.
(16) Position a magnet to the end of the injection
(18) With the injection pump at the correct
pump shaft. Install the special bearing and thrust
plunger lift setting, use special gear puller tool
washer kit #6862 (Fig. 56) over the injection pump
#L-4407A to pull the injection pump gear off the
shaft in this order: 1 thrust washer-1 bearing-1
taper of the injection pump input shaft. Leave the
thrust washer. The thrust washer/bearing kit is used
gear puller installed (Fig. 57). After the gear has
to prevent the pump gear from rotating on the pump
been pulled, ensure the lift setting has not changed.
shaft when tightening the pump nut (step 22). Rein
stall pump shaft nut allowing some clearance
between the thrust washers. Do not tighten nut at
this time.
Fig. 57 Gear Puller Tool Installed

(19) Rotate the engine 20 to 30 degrees counter
clockwise, then rotate the engine back clockwise to
TDC (Fig. 58). This removes backlash from the
geartrain.
The fuel pump gear and pump shaft tapers
must be absolutely clean, dry and free of any
PUMP SHAFT oil or dirt. Oil or dirt will prevent seating of the
J9514-65 taper and will result in possible slippage of the
gear.
Fig. 55 Positioning Magnet to Pump Shaft (20) Loosen, but do not remove the gear puller tool
bolts. Using the gear puller, rotate pump gear coun-
FUEL SYSTEM 14 - 91
mm
H V I C E PROCEDURES (Continued)
Fig. 61 Tightening Pump Nut

Fig. 58 Rotating Crankshaft (22) Tighten the pump shaft nut to 15 N-m (11 lb.
terclockwise by hand (Fig. 59), while pushing the ft.) torque to seat the gear to the pump shaft taper
gear onto the pump shaft. This will remove backlash (Fig. 61).
between the injection pump and camshaft gears. (23) Remove injection pump shaft nut. Use a mag
net on the end of the shaft while removing (Fig. 55).
(24) Remove special bearing and thrust washers
#6862 from pump shaft. Use a magnet on the end of
the shaft while removing.
(25) While preventing the engine from rotating
with the barring tool, tighten the shaft nut to 165
N-m (122 lb. ft.) torque (Fig. 61).
(26) Repeat steps 12 and 13 to verify that the final
timing setting is correct. I f the setting is not correct,
repeat steps 15 through 25.
(27) Remove the dial-indicator and adaptor from
the injection pump.
CAUTION: THE FOLLOWING INSTALLATION AND

;
J9514-88 TORQUING PROCEDURE MUST B E FOLLOWED
EXACTLY. IMPROPER INSTALLATION OF THE DELIV
Fig. 59 Rotating injection Pump Gear ERY VALVE WILL RESULT IN DAMAGE OR LEAKS.
(21) Hand tighten the pump shaft nut (Fig. 60).
(28) Install a new metal delivery valve washer into
Remove the gear puller (Fig. 60).
the fuel pump.
THRUST (29) Install the delivery valve assembly on top of
WASHERS the sealing washer (Fig. 62) or (Fig. 48).
J9514-89
J9514-91
Fig. 68 Removing Gear Puller Tool
Fig. 62 Delivery Valve Assembly
14 • 92 FUEL SYSTEM BR
(30) Lubricate the threads and clamping surface of THROTTLE LINKAGE ADJUSTMENT—DIESEL
the delivery valve holder with a few drops of S A E 90 ENGINE
hypoid gear oil. Do not lubricate the metal deliv The linkage rod (Fig. 65) connecting the throttle
ery valve washer or its seating area. lever to the fuel injection pump lever is adjustable.
(31) Install the delivery valve holder assembly tak
ing care not to displace the delivery valve spring, fill CAUTION: Before adjusting the fuel injection pump
piece, or any shims (Fig. 63). throttle linkage, verify that engine is set at correct
low idle speed. Refer to Idle Speed Adjustment.
This can be found in the Diesel Engine—General
Diagnosis section of this group.
(1) Verify low idle speed.

(2) Disconnect throttle cable socket from lever ball
stud on throttle lever (Fig. 66).
THROTTLE LEVER-TO-
THROTTLE INJECTION PUMP LEVER
LEVER LINKAGE ROD
BALL
J9514-92
Fig, 68 Delivery Waive Holder

(32) Pre-tighten the delivery valve holder to 40
N-m (29 lb. ft.) torque (Fig. 64). Next, in one motion,
tighten the holder to 115 N-m (85 ft. lbs.) torque (Fig.
64).
40 N°m
[29 FT-LBS]
THROTTLE
LEVER
RIGHT-HAND-
THREADED
THROTTLE FLAT NUT
POSITION LEFT-HAND-
SENSOR THREADED
NUT J9414-67
Fig. 64 Tightening Delivery Waive Holder
(33) Install remaining engine components removed Fig. 65 Diesel Throttle Lever Linkage Adjustment-
during the timing process. Leave the injector end of Typical
the #1 high-pressure fuel line loose to facilitate (3) Measure the distance between the center of the
bleeding the air out of the system. lever ball and the rear face of the cable mounting
bracket (Fig. 67). Dimension should be 126.5 mm (5.0
WARNING: THE PRESSURE OF THE FUEL IN THE inches.) I f not, proceed to following step.
LINE IS SUFFICIENT TO PENETRATE THE SKIN (4) To prevent damage to ends of linkage, attach
AND CAUSE SERIOUS BODILY HARM. locking-type pliers to the flat (Fig. 65) located on the
linkage rod before loosening locknuts.
(34) Crank the engine until fuel is observed at the (5) Loosen the right-hand-threaded nut (Fig. 65).
#1 injector. Tighten the high-pressure line at the
(6) Loosen the left-hand-threaded nut (Fig. 65).
injector. Start the engine and check for leaks.
B R — — — — — FUEL SYSTEM 14-93
FRONT OF VEHICLE
126.5 MM
(5.0 INCHES)
Fig. 66 Diesei Throttle Cable at Injection Pump—

Typical
(7) Rotate the flat on the linkage rod (lengthen or
shorten) to achieve proper linkage adjustment (Fig. CENTER REAR FACE
67). Tighten both nuts after adjustment. OF BALL OF BRACKET J9414-68
(8) With the engine OFF, operate the throttle
from accelerator pedal and check for throttle lever Fig. 67 Diesei Linkage Measurement—Typical
action and binding. Be sure throttle lever stop is REMOVAL AND INSTALLATION
against the low idle speed screw after throttle is
released. ACCELERATOR PEDAL
(9) Be sure of wide open throttle (WOT) when Refer to the Fuel Delivery System—Gasoline
accelerator pedal is pressed to the floor. This is Engine section for procedures.
checked by observing throttle lever breakover posi
tion. Proceed to the following: FUEL DRAIN MANIFOLD
(a) Key OFF and engine OFF for this test.
(b) Two people are needed for this test. From REMOVAL
inside of the vehicle, press the accelerator pedal (1) Remove the two nuts retaining the nameplate/
about half-way to the floor. Movement of both the cover to the top of the six engine valve covers (Fig.
throttle lever and throttle lever-to-injection pump 68). Remove nameplate/cover from engine.
lever linkage rod (Fig. 65) should be observed. (2) Remove drain manifold fitting screws (bolts) at
(c) Continue to press the accelerator pedal to the each of the six injectors (Fig. 69).
floor. I f throttle lever breakover is operating cor (3) Remove the fuel drain manifold holddown
rectly, the throttle lever-to- injection pump lever clamp mounting bolt at the top/rear of intake mani
linkage rod should have stopped moving while the fold.
throttle lever continues to move towards the rear (4) Remove the fuel drain manifold banjo fitting at
of vehicle. the top of fuel filter/water separator (one bolt) (Fig.
(10) Again, check and verify low idle speed. Adjust 70).
i f necessary. (5) Remove fuel drain manifold fitting washers at
( 1 1 ) Diesel engines equipped w i t h an auto each fuel injector.
matic transmission: A throttle position sensor (6) Remove manifold from engine.
(TPS) is used with this driveline combination. TPS
voltage must now be tested. Refer to Throttle Posi
tion Sensor Removal/Installation.
14 - 94 FUEL SYSTEM — _ BR
REMOVAL A U D INSTALLATION (Continued)
NAMEPLATE/COVER
Fig, 68 Nameplate/Cover—Diesel
Fig. 70 Drain Manifold and Fuel Filter/Water

Separator
located on the left/rear side of the engine and below
the intake manifold (Fig. 70).
REMOVAL
(1) Partially drain the filter/separator. Refer to the
following: Draining Water from Filter.
DRAINING WATEE FROM FILTER; The filter
should be drained whenever the water-in-fuel warn
ing lamp remains illuminated. (Note that the lamp
Fig. 69 Fuel Drain Manifold Fittings—Typical will be illuminated for approximately two seconds
INSTALLATION when the ignition key is initially placed in the ON
(1) Using new seals/washers on all fittings, assem position for a bulb check). The drain valve can also
ble fuel drain manifold in reverse order of disassem be used to drain excess fuel from the filter when
bly. replacement of the filter is necessary.
(2) Tighten drain manifold fitting screws (bolts) at There is a drain valve and drain hose located at
the injectors to 8 N-m (6 ft. lbs.) torque. the bottom of the water-in-fuel (WIF) sensor (Fig.
(3) Tighten drain manifold holddown clamp screws 71). Place a drain pan under the drain hose. With
(bolts) to 13 N-m (10 ft. lbs.) torque. the engine not running, push up on the drain
(4) Install nameplate/cover. valve (Fig. 71) to remove the water from the filter/
separator. Hold the drain valve open until all water
FUEL FILTER/WATER SEPARATOR and contaminants have been removed and clean fuel
Refer to the maintenance schedules in Group 0 in exits the drain. Dispose of mixture in drain pan
this manual for the recommended fuel filter/water according to applicable regulations.
separator replacement intervals. (2) Remove the drain hose at the drain valve (Fig.
The combination water-in-fuel sensor and fuel fil 71).
ter/water separator is screwed onto a metal housing
BR FUEL SYSTEM 14 • 95
Fig. 71 Drain Valve at Fuel Filter/Water Separator Fig. 73 Fuel Filter/Water Separator O-ring
(3) Disconnect the electrical connector from the
WIF sensor at the bottom of the filter (Fig. 72). FUEL FILTER/
DRAIN
VALVE
J9414-90
Fig. 74 WIF Sensor a n d Drain Vaive Assembly

essary (temporary rough engine r u n n i n g may
Fig. 72 Electrical Connector—WIF Sensor occur), i f necessary, refer to the A i r Bleed Pro
(4) Remove (unscrew) the filter/separator and WIF cedure i n this section of the group for proce
sensor as one assembly from the filter housing (Fig. dures.
72). (3) Fill filter/separator with clean fuel.
(5) Remove the o-ring seal from the filter housing (4) Apply a light film of clean unused engine oil to
(Fig. 73). the filter/separator seal.
(6) Drain the filter/separator. ( 5 ) Install a new o-ring seal to the filter/separator
(7) Remove the WIF sensor, o-ring and drain valve housing (Fig. 73).
assembly from the filter/separator (Fig. 74). (6) Install filter/separator to housing. Tighten fil
(8) Inspect the WIF sensor probes. Clean contami ter/separator one-half turn after i t makes contact
nants from sensor probes if necessary. Replace sensor with the housing. Tighten by hand only.
if probes will not clean up. (7) Connect electrical connector to WIF sensor.
(8) Connect drain hose to drain valve.
INSTALLATION
(1) Install a new o-ring seal on WIF sensor. FUEL TANK
(2) Install WIF sensor/drain valve assembly into Refer to Fuel Tank—All Engines in the Fuel Deliv
new filter/separator. ery System—Gasoline engines section for procedures.
I f the new fuel filter/water separator is not
filled w i t h clean fuel before i t is installed, man
u a l a i r bleeding of the fuel system may be nec-
14 - i i FUEL SYSTE1 mm
RBM&mt mm I N S T A L L A T I O N (Continued)
FUEL TANK MODULE INSTALLATION
REMOVAL CAUTION: Whenever the fuel tank module Is ser

viced, t h e lockout and rubber gasket must be
CAUTION; Whenever t h e fuel tank module is ser replaced.
viced, t h e plastic locknut and rubber gasket must
be replaced. (1) Using a new gasket, position the fuel tank
module into the opening i n fuel tank. The fuel line
(1) Drain the fuel tank. Refer to Draining Fuel connectors, the pressure relief/rollover valve and the
Tank in Fuel Tanks—All Engines for procedures. fuel gauge electrical connector should all be pointed
(2) Remove fuel tank. Refer to Fuel Tanks—All to the drivers side of the vehicle before tightening
Engines for procedures. locknut.
(3) Note the direction of the: fuel line connectors, (2) Position new locknut over top of fuel tank mod
the pressure relief/rollover valve and the fuel gauge ule.
electrical connector. These should all be pointed to (3) Tighten locknut.
the drivers side of the vehicle. (4) Install fuel tank. Refer to Fuel Tanks—All
(4) The plastic locknut on the fuel tank module is Engines for procedures.
threaded onto the fuel tank. Remove the locknut
(Fig. 75). The tank module will spring up when the AUXILIARY FUEL SUPPLY FITTING
locknut is removed. An auxiliary (capped) fuel supply fitting is located
(5) Remove module from fuel tank. on the top of the fuel tank module (Fig. 75). This fit
ting will be available only on: diesel powered models,
and models with either a 5.9L V-8 heavy duty or 8.0L
V-10 engine, and all cab-chassis models. This fitting
supplies a non-pressurized auxiliary fuel source.
FUEL HEATER
The fuel heater element assembly is located inside
of the fuel heater housing and above the pre-filter
(Fig. 77). The fuel temperature sensor is located at
the top of the fuel heater housing (Fig. 77).
Fig. 75 Top View of Fuel Tank Module—Diesei

SCREWS FUEL FILTER J9414-33

Fig. 77 Fuel Heater and Temperature Sensor
Location
Fig. 76 Fuel Gauge Sending Unit—Typical

REMOVAL FUEL SHUT-OFF
FUEL HEATER S O L E N O I D RELAY
(1) Disconnect both negative battery cables at both
batteries.
(2) Remove starter motor. Refer to Group 8B for
procedures.
(3) Disconnect the electrical connector at the front
of fuel heater housing (Fig. 77).
(4) Place a drain pan below the fuel heater.
(5) A machined hex is located on the bottom of the pre-
filter housing (Fig. 78), From under the vehicle, attach a
socket to this hex and remove (unscrew) the pre-filter.
(6) Remove the fuel heater assembly from housing.
Fig. 79 Fuel Heater Relay—Diesel
Fig. 78 Fuel Heater and Pre-Filter

INSTALLATION
Reverse the removal procedure for heater element
installation.
FUEL HEATER RELAY

The fuel heater relay is located in the engine com
REMOVAL
batteries.
(2) Disconnect the electrical connector at the relay.
(3) Remove the relay from the mounting bracket.
M J T
INSTALLATION CENTER TERMINAL 9I K !oP

B O L T S 2
IS OUTPUT WIRE ( ) J9414-91
(1) Install the relay to the mounting bracket.
(2) Connect the electrical connector. Fig. 80 Throttle Position Sensor—Diesel
(3) Connect battery cables to both batteries.
(3) Disconnect the electrical connector at fuel shut
FUEL INJECTION P U I P down solenoid. (Fig. 81).
(4) Disconnect the main engine wiring harness at
REMOVAL top of injection pump and position to the side.
(1) Disconnect both negative battery cables at both (5) Remove the metal intake manifold-to-inter-
batteries. cooler connecting tube.
(2) Disconnect electrical connector at throttle posi (6) Remove the engine oil dipstick tube mounting clamp
tion sensor on side of injection pump (if equipped and bolt (Fig. 82). Position dipstick tube to the side.
with automatic transmission) (Fig. 80). (7) Disconnect the two air heater cable nuts (Fig. 82).
(10) Disconnect turbocharger wastegate line and
SENSOR ELECTRICAL vacuum line from air fuel control (AFC) valve at rear
CONNECTOR of injection pump (Fig. 83).
AIR FLOW
CONTROL VALVE
INTAKE
MANIFOLD p u E L

SOLENOID ELECTRICAL
CONNECTOR J9414-93

AIR CABLE INTAKE MANIFOLD
HEATER NUTS (2) BOLTS (5)
ASSEMBLY
Fig. 83 Wastegate and Vacuum Lines
LOWER PART (11) Remove the fuel supply line at both ends
OF INTAKE (injection pump and fuel filter/water separator) (Fig.
MANIFOLD
\ 1ES (2) 84). For procedures, refer to Fuel Injection Pump
Supply Line in this group. Place a rag beneath the
CABLE fitting to catch excess fuel.
MOUNTING
STUDS (2)
DIPSTICK TUBE
BOLT
UPPER PART OF
INTAKE MANIFOLD J9414-105
Fig. 82 Intake Manifold Air Heater

(8) Remove the five intake manifold bolts (Fig. 82).
Discard both of the old air heater base gaskets. J9414-114
(9) Remove the throttle control bracket, cables and
linkage assembly from the side of pump (three bolts). Fig. 84 Fuel Injection Pump Supply Line
Position the assembly to the side.
REMOVAL A N D INSTALLATION fContinued)

(12) Remove the overflow valve and fuel return (14) Disconnect the engine oil supply line at side of
line at pump (Fig, 85). Place a rag beneath the fitting pump (Fig. 87).
t o catch e x c e s s fuel.
Fig. 87 Engine Oil Supply Line—Pump Mounting

Fig. 85 injection Pump Overflow Valve Nuts
(13) Disconnect the s i x (6) high-pressure fuel lines (15) Remove the oil fill tube bracket mounting bolt
from the fuel delivery valve holders at the top of (Fig. 88).
injection pump (Fig. 86). For procedures, refer to (16) Remove oil fill tube from tube-to-gear housing
High-Pressure Fuel Lines in this group. Place a rag adapter (Fig. 88). Tube is removed by screwing coun
beneath the fittings to catch excess fuel. terclockwise from adapter.
Fig. 88 Oil Fill Tube, Adapter and Mounting Bracket

(17) Remove oil fill tube adapter from gear hous
ing (Fig. 88). Adapter is removed by screwing coun
terclockwise from gear housing.
INJECTION PUMP
J9414-116
(18) The engine is equipped with a built-in
moveable timing pin. This pin is located above the
Fig. 86 Fuel Delivery Valve Holders and Pressure power steering pump, below and to the inside of the
Lines fuel injection pump, on the rear of the cam gear
housing (Fig. 89). The pin will engage into a
14 - 1 0 0 FUEL SYSTEM BR

machined hole in the back of the camshaft gear (Fig. (21) The opening for the barring tool is located in
90). I t is designed to position the engine to TDC (Top the rear flange of engine on exhaust manifold side
Dead Center) on the compression stroke of number 1 (Fig. 91). Remove the rubber access plug covering
cylinder. this opening.
Fig. 91 Rotating Engine with Barring Tool—Typical

(22) Insert the barring tool into the flywheel hous
ing opening (Fig. 91).
(23) While holding tension on the timing pin
(towards front of engine), very slowly rotate the
engine (counterclockwise as viewed from front) with
Fig. 89 Timing Pin and Location the barring tool. Rotating the barring tool counter
clockwise will rotate the crankshaft clockwise. Con
MACHINED HOLE
tinue to rotate until the timing pin drops into the
machined hole in the back of the camshaft gear.
When the pin aligns to the gear, the engine is now at
the TDC position (compression stroke) at cylinder
number 1.
CAUTION: When installing the fuel injection pump

and to achieve proper injection pump timing, the
engine MUST be in the TDC position (compression
stroke) at cylinder number 1.
Before proceeding to the next step, and to

prevent shearing of the timing pin, temporarily
remove the timing pin from the back of the
gear.
(24) Remove the nut and washer retaining the
injection pump gear to the injection pump shaft (Fig.
92).
(25) Place a shop towel below the retainer nut i n
the gear housing cover opening to prevent the nut or
washer from falling into the gear housing.
Fig. 90 Back of Camshaft Gear—Typical CAUTION: If the gear retainer nut or washer drops
(19) Remove the rubber air tube connecting the into gear housing, cover must be removed to
turbocharger to the air cleaner housing. retrieve them before engine is started.
(20) The engine can be rotated with a barring tool
(26) Use a T-bar type puller (Fig. 93) to separate
such as Snap-On No. SP371, MTE No. 3377371
the injection pump gear from the injection pump
(Cummins Tool Division), or an equivalent.
shaft. Attach two M8 X 1.24 M M (metric) screws
INJECTION
PUMP
GEAR
T I M I N G GEAR
COVER J9414-4
Fig. 92 injection Pump Gear Washer and Nut Fig. 94 Pump Mounting Bolts
through the puller and into the two threaded holes shaft on the aluminum gear housing when
supplied in the pump gear. Pull the injection pump removing pump.
gear forward until i t loosens from the injection pump (30) Clean the injection pump o-ring mounting sur
shaft. Pull on the gear only enough to loosen it faces on both the gear housing'and pump.
from the injection pump shaft. Pulling the gear
too far may cause damage or breakage to the INSTALLATION
gear cover.
CAUTION: Before installing the injection pump, be
sure that number 1 cylinder is at the Top Dead Cen
ter (compression stroke) position. Engage the tim
ing pin on the rear of the gear cover (Fig. 89) into
the rear of the camshaft gear. Rotate crankshaft if
necessary.
Before injection pump installation, it must be set

(pump shaft rotated) to a certain position to attain
accurate pump timing. Remove the access plug from
the side of pump (Fig. 95). Stored behind this access
plug is a plastic timing pin tool (Fig. 96). This tool is
used to align the injection pump timing tooth (Fig.
97) to the center of access hole.
Installing Original Pump: I f the original pump
is being reinstalled, the pin tool should already be
mounted with the slotted end facing outward (Fig.
Fig. 93 Separating Injection Pump Gear from Pump
96). When the position of this tool has been reversed,
Shaft
with the slotted end facing inward, it is used as a
(27) Eemove the two (2) injection pump-to-lower pump timing pin tool.
mounting bracket bolts (Fig. 94). Installing New or Rebuilt Pump: I f a new or
(28) Remove the four (4) injection pump-to-gear rebuilt pump is being installed, the pump should
housing mounting nuts (Fig. 87). have been shipped with the slotted end of the timing
(29) Remove the injection pump from gear hous pin tool engaged to the timing tooth in the pump.
ing. Take care not to nick the injection pump To set injection pump timing on an original pump
or when checking timing on a new pump, rotate the
>
14 -102 F U E L m^m - — - -
DELIVERY OIL FILL PLUG
J9414-77
Fig. 97 injection Pump Timing Tooth

access plug. New pumps should have been shipped
with this tool already engaged.
(1) I f the original pump is being installed, check
the condition of the rubber o-ring at pump mounting
area.
Fig. 95 injection Pump Access Piug (2) Apply clean engine oil to the injection pump
pump shaft until the timing tooth appears in the cen mounting flange opening in gear cover housing to
ter of the plug opening (Fig. 97). Install the slotted allow easier pump installation (Fig. 98). Also apply
end of the timing pin tool over the timing tooth. The engine oil to the pump o-ring seal at pump mounting
pump shaft may have to be rotated slightly to align area. The machined tapers on both the injection
the tool to the tooth. Do not force the slots in the tool pump shaft and injection pump gear must be
over the timing tooth. dry, clean and free of any d i r t or o i l . This w i l l
After the tool has been temporarily installed to ensure proper gear-to-shaft tightening.
the timing tooth, install and loosely tighten the
Fig. 96 injection Pump Timing Pin Toot

BR FUEL SYSTEM 14 - 1 0 3

INJECTION (11) After the injection pump gear has received a
PUMP final tightening, verify injection pump timing.
GEAR (a) Rotate the engine counterclockwise with the
barring tool (clockwise as observed at the crank
PUMP M O U N T I N G shaft from the front of vehicle). Continue rotating
STUDS engine until the timing pin aligns into hole at rear
of camshaft gear (Fig. 90). The engine is now at
TDC of number cylinder 1.
(b) With the timing pin aligned into the rear of
the camshaft gear, the timing tooth should also be
centered in the access hole on the side of the injec
tion pump (Fig. 97). Install timing pin tool (Fig. 96)
to verify.
(c) I f the timing pin tool will not fit into the tim
ing tooth in the pump, the pump gear nut must be
removed. Loosen the pump gear from the pump
shaft with the T-bar puller tool. With the gear loos
ened, rotate the injection pump shaft until i t aligns
to the center of access hole on side of pump.
Tighten injection gear nut and remove barring tool.
PUMP M O U N T I N G
FLANGE J9414-5 (12) Remove the timing pin tool from the pump.
Reverse the position of this tool (Fig. 96). The slotted
Fig. 98 Apply Oil to Gear Cover part of tool * should be facing outward and will be
stored in pump in this direction. Place tool back into
(3) Position the pump assembly to the mounting pump. Install access plug and its sealing washer.
flange on gear cover while aligning the injection Tighten plug to 15 N-m (11 ft. lbs.) torque.
pump shaft through the back of injection pump gear. (13) Install the engine oil supply line and fuel
(4) Install the four pump mounting nuts finger return line/overflow valve to pump.
tight. Do not attempt to tighten (pull) the pump (14) Install the six high-pressure fuel lines to the
to the gear cover using the mounting nuts. top of pump. Tighten lines to 30 N-m (22 ft. lbs.)
Damage to pump or gear cover may occur. The torque.
pump must be positioned flat to its mounting (15) Install the low-pressure fuel supply line to
flange before attempting to tighten mounting pump.
nuts. (16) Install the turbocharger wastegate line and
(5) Install two (vertical) pump mounting bracket AFC sensing line at the pump.
bolts finger tight. (17) New or rebuilt P7100 series fuel injection
(6) Tighten the four pump mounting nuts to 24 pumps must be pre-lubricated before operation.
N-m (18 ft. lbs.) torque. Tighten the two pump Failure to do so may result in pre-mature gov
mounting bracket bolts. To prevent damage to ernor wear.
pump and mounting flange, tighten the pump (a) Remove the 10 mm hex plug (oil fill plug) on
mounting nuts first. • the top of the injection pump governor (Fig. 95).
(7) Install injection pump drive shaft-to-injection (b) Add 750 ml (25 ounces) of clean engine oil
pump gear retaining nut and washer. Do a prelim through this opening.
inary tightening of this nut to 10 to 15 N«m (7 to (c) Install oil fill plug and tighten to 28 N-m (21
11 ft. lbs.) torque. Do not over tighten. This is ft. lbs.) torque.
not the final tightening torque. To prevent dam (18) Install the throttle linkage assembly to pump.
age to the timing pin, do not exceed this Tighten bolts to 24 N-m (18 ft. lbs.) torque.
torque. (19) Connect electrical connector to fuel solenoid.
(8) Disengage the timing pin from the rear of cam (20) Connect the main engine wiring harness at
shaft gear by pulling i t straight back. top of injection pump.
(9) Remove the access plug from injection pump (21) Install the engine oil dipstick tube mounting
(Fig. 95) and remove timing pin tool from pump. clamp and bolt at the opening to the intake manifold.
(10) Do a final tightening of the injection pump (22) Install oil fill tube and tube adapter.
gear-to-injection pump shaft nut. Tighten to 165 N-m (23) Install oil fill tube bracket and mounting bolt.
(122 ft. lbs.) torque. Use the barring tool to prevent (24) Install electrical connector to throttle position
the engine from rotating when tightening gear. sensor (if equipped).

(25) Install air cleaner housing-to-turbocharger
tube at air cleaner housing.
(26) Using a new gasket, install air heater assem
bly (five bolts).
(27) Install intake manifold-to-intercooler tube.
(28) Check and adjust throttle linkage. Refer to
Throttle Position Sensor in this group.
(29) Bleed air from fuel system. Refer to the Air
Bleed Procedure in this section of the group.
(30) Adjust the low idle speed i f required. Refer to
Idle Speed Adjustment.
(31) inspect throttle linkage to be sure that the
control lever is opening to the full open position.
(32) Some engine oil was lost when removing
pump. Check and adjust engine oil level. J9414-98
FUEL INJECTORS Fig. 100 Loosening Injector Body
REMOVAL
(1) Disconnect both negative battery cables from
both batteries.
(2) Remove the high-pressure fuel lines. Refer to
High-Pressure Fuel Lines in this section.
(3) Remove the fuel drain manifold. Refer to Fuel
Drain Manifold in this section.
(4) Thoroughly clean the area around the injector.
CAUTION: When rust has formed on the fuel Injec
tor nut (Fig. 99), the injector (when being removed)
can rotate in the cylinder head. This may cause
damage to the cylinder head bore. Use a rust pen
etrating solvent before attempting to loosen a
rusted holddown nut. J9414-99
Fig. 101 Loosening Injector

(7) I t may be necessary to tap the injector with an
injector puller tool (Fig. 102). Use Cummins Tool
number 3823276 or equivalent.
FUEL
INJECTOR
PULLER
TOOL.
J9414-97
Fig. 99 Loosening Injector Nut

(5) Hit the injector body with a brass drift to
loosen i t (Fig. 100).
(6) Hold the injector body with one wrench while J9414-100
removing the injector nut with another (Fig. 101).
Fig. 102 Removing Injector with Puller Tool
HEH©WAL AND INSTALLATION fContinued)
INSTALLATION
(1) Clean the injector cylinder head bore with spe
cial Cummins wire brush tool or equivalent (Fig.
103).
Fig. 103 Cleaning Cylinder Head Injector Bore

(2) Install a new copper washer on injector (Fig.
104).
Fig. 106 Installing Injector

(8) Connect the negative battery cables to both
batteries.
J9114-50 (9) Bleed the air from the high-pressure lines.
Refer to High- Pressure Line Bleeding in the Air
Fig. 104 Injector Washer Bleed Procedure section at the front of this section of
the group.
(3) Apply a coating of anti-seize compound to the
threads of the injector holddown nut and between the FUEL SHUTDOWN SOLENOii
top of the nut and injector body (Fig. 105).
(4) Install the injector into the cylinder head. Align REMOVAL
the tab on the injector to the notch i n the cylinder The fuel shutdown solenoid is mounted to a
bore (Fig. 106). Certain types of injectors may have bracket located on the side of the fuel injection pump
an o-ring located above the holddown nut (Fig. 106). (Fig. 107).
After tightening the injector, push the o-ring into the (1) Disconnect the solenoid electrical connector
groove on the top of the injector. (Fig. 107). •
(5) Tighten the injector holddown nut to 60 N-m (2) Disconnect clip at injection pump shutdown
(44 ft. lbs.) torque. lever (Fig. 108).
(6) Connect the fuel drain manifold to the injec (3) Remove two solenoid mounting bolts.
tors. Refer to Fuel Drain Manifold i n this section. * (4) Remove solenoid from mounting bracket.
(7) Connect the high-pressure fuel lines. Refer to
High-Pressure Fuel Lines in this section.
14 - 106 FUEL SYSTEM
FRONT OF ENGINE AIR TEMPERATURE SOLENOID SHAFT ADJUSTMENT
SENSOR
SENSOR ELECTRICAL After replacing the fuel shutdown solenoid, the
CONNECTOR solenoid shaft length must be checked and i f neces
sary, adjusted.
(1) Turn the ignition switch ON.
(2) Pull up (by hand) and hold on the solenoid
lever (Fig. 109). If the solenoid is operating cor
rectly, it should remain in the U P position with
the key in the ON position.
FUEL
SHUTDOWN
SOLENOID
INTAKE
MANIFOLD p u E L

SOLENOID ELECTRICAL J9414-93
J y 4 l 4 y j
CONNECTOR
FUEL SHUTDOWN MOUNTING

SOLENOID BOLTS
HOLD SOLENOID
LEVER IN
"UP" POSITION J9414-81
SHUTDOWN Fig. 109 Fuel Shutdown Solenoid Lever in Up

LEVER v Position
(3) Take a measurement from the bottom of the
solenoid mounting bracket to the top of the injection
pump shutdown lever pin (Fig. 110).
(4) Dimension should be 66.9 mm (2.64 inches).
(5) I f adjustment is necessary, loosen the shaft
locknut and rotate the adjustment nut (Fig. I l l ) to
attain dimension.
FUEL SHUTDOWN SOLENOID RELAY

The fuel shutdown solenoid relay is located in the
LOCKNUTS CUP
J9414-92 engine compartment near the brake master cylinder
(Fig. 112).
Fig. 108 Fuel Shutdown Solenoid Removal/
installation MEMOWAL
INSTALLATION
batteries.
(1) Position solenoid to mounting bracket and (2) Disconnect the electrical connector at the relay.
injection pump lever. (3) Remove the relay from the mounting bracket.
(2) Install clip at injection pump lever.
(3) Install and tighten two mounting bolts. INSTALLATION
(4) Check and adjust the shaft length of the sole (1) Install the relay to the mounting bracket.
noid. Refer to the following procedure: (2) Connect the electrical connector.
(3) Connect battery cables to both batteries. .
BR — • • • FUEL SYSTEM 14 • 107

FUEL SHUT-OFF
FUEL HEATER S O L E N O I D RELAY
BOTTOM OF BRACKET
Fig. 112 Fuel Shutdown Solenoid Relay—Diesel

The fuel transfer pump is located on the left side of
the engine and above the starter motor (Fig. 113).
J9414-131 The mounting bracket/spacer for the fuel heater
assembly is located between the engine block and the
Fig. 110 Solenoid Measurement
fuel transfer pump (Fig. 114). The fuel heater hous
ing and its bracket assembly must also be removed
ADJUSTMENT when removing fuel pump.
NUT
LOCKNUT J9414-132
Fig. 111 Solenoid Adjustment

FUEL TRANSFER PUMP Fig. 113 Fuel Transfer Pump Location
For operation of the fuel transfer pump primer but
ton, refer to Fuel Transfer Pump Description/Opera
tion.
14 -108 FUEL SYSTEM BR
FUEL TANK PiESSUFtE FtELlEF/ROLLOWER WALWE
Refer to Fuel Tank Module for procedures.
HIGH-PRESSURE FUEL LINES

All high-pressure fuel lines are of the same length
and inside diameter. Correct high-pressure fuel line
usage and installation is critical to smooth engine
operation.
CAUTION: The high-pressure fuel lines must be

clamped securely in place in the holders. The lines
cannot contact each other or other components. Do
not attempt to weld high-pressure fuel lines or to
repair lines that are damaged. Only use the recom
J9414-96 mended lines when replacement of high-pressure
fuel line is necessary.
Fig. 114 Pump Removal/installation
REMOVAL REMOVAL
(1) Disconnect both negative battery cables at both (1) Disconnect both negative battery cables from
batteries. both batteries.
(2) Remove starter motor. Refer to Group 8B for (2) Remove the nameplate/cover from the top of
procedures. the six engine valve covers (two nuts) (Fig. 115).
(3) Place a drain pan below the pump.
(4) Remove the fuel line fittings at the top of both NAMEPLATE/COVER
NAMEPLATE/COVER
the fuel pump and fuel heater housing (Fig. 114). NUTS (2)
(5) - Remove the fuel hose clamps and rubber fuel #6 CYLINDER
VALVE COVER
hose (fuel heater housing-to-fuel pump)'(Fig. 114).
(6) Remove the two mounting bolts (Fig. 114).
(7) Remove the fuel pump and fuel heater assem
bly from the engine as one unit.
CAUTION; Do not allow pump plunger to catch on

edge of hole in cylinder block during removal.
Plunger may slide out and drop into engine.
INSTALLATION
(1) Clean the mating surfaces of the fuel heater
mounting bracket, the fuel pump and the engine
block of any gasket material.
(2) Position the new gaskets, the fuel heater hous
RUBBER
ing mounting bracket and the fuel pump to the METAL ADAPTER
CLAMPS (2) INTAKE
engine.
TUBE
(3) Install the two mounting bolts into the engine. J9414-73
Tighten to 24 N-m (18 ft. lbs.) torque. As these bolts
are tightened, the plunger w i t h i n the fuel pump Fig. 115 Nameplate/Cover—Diesei
is being compressed. Tighten these two bolts (3) Remove the necessary clamps holding the lines
alternately to prevent damage to the fuel pump to the engine.
housing. (4) Clean the area around each line. Disconnect
(4) Install fuel line fittings to pump and fuel each line at the top of each fuel injector (Fig. 116).
heater. Tighten to 24 N-m (18 ft. lbs.) torque. (5) Disconnect each high-pressure line fitting at
(5) Install starter motor. Refer to Group 8B for each fuel injection pump delivery valve holder (Fig.
procedures. 117).
(6) Connect battery cables at both batteries. (6) Very carefully remove each line from the
(7) Bleed air from fuel system. Refer to the Air engine. Do not bend the line while removing.
Bleed Procedure.

INSTALLATION
FUEL HIGH-PRESSURE (1) Carefully position each high-pressure fuel line
DRAIN FITTING FUEL LINE
MANIFOLD to the fuel injector and fuel injection pump delivery
valve holder in the correct firing order. Also position
each line in the correct line holder.
(2) Loosely install the line clamp isolator and
bracket holder bolts.
(3) Tighten each line at the delivery valve holder
(4) Tighten each line at the fuel injector to 24 N-m
CAUTION: Be sure the lines are not contacting

each other or any other component.
(5) Tighten the clamp bracket bolts to 24 N-m (18

ft. lbs.) torque.
(6) Bleed air from the fuel system. Refer to High-
Pressure Fuel Line Bleeding in the Air Bleed Proce
dure portion of this section.
FUEL INJECTOR
J 9 4 1 4 - 1 17
THROTTLE CABLE
Fig. 116 Fuel Lines at Fuel Injectors
CAUTION: Be careful not to damage or kink the
FUEL DELIVERY cable core wire (within the cable sheathing) while
HIGH-PRESSURE
FUEL LINES (6)
FITTINGS (6) VALVE HOLDERS (6) servicing accelerator pedal or cables.
REMOVAL
118). The plastic cable retainer snaps into pedal the
arm.
CABLE FRONT O F
STOP C^-v VEHICLE
PINCH T W O
TABS
FOR
CABLE REMOVAL
INJECTION PUMP
J9414-H6
Fig. 117 Fuel Delivery Waive Holders and Pressure

Lines
CAUTION: Be sure that the high-pressure fuel
lines are installed in the same order that they were
removed. Prevent the injection pump delivery vaive
holders from turning when removing or installing
high-pressure lines from injection pump.
THROTTLE
PEDAL
ARM J9414-42
Fig. 118 Cable Removal/Installation

14 - 1 1 0 FUEL SYSTEM BR
(2) Remove the cable core wire at the pedal arm. to the accelerator pedal arm, note the index tab on
(3) From inside the vehicle, pinch both sides of the the pedal arm (Fig. 118). Align the index slot on the
plastic cable housing retainer tabs at the dash panel plastic cable retainer to this index tab.
(Fig. 118).
(4) Remove cable housing from dash panel and
pull the cable into the engine compartment. SPECIFICATIONS
(5) Remove the throttle cable socket at fuel injec
tion lever ball (Fig. 119). ENGINE DATA PLATE SPECIFICATIONS
FRONT O F VEHICLE on the Engine Data Plate, and the specifications used
CABLE RUBBER in this manual, use specifications on data plate. The
CABLE
SOCKET GROMMET
MOUNTING Engine Data Plate is located on the engine timing
BRACKET gear cover (Fig. 120).
LEVER
BALL
TIMING
GEAR
COVER
FUEL
INJECTION
PUMP
TORSION
SPRING J9414-43
Fig. 120 Engine Data Plate Location
Fig. 119 Throttle Cable at Injection Pump—Diesel FUEL TANK CAPACITY
Engine
Models Liters U S. Gallons
(6) A rubber/plastic grommet is molded to the
cable (Fig. 119). This grommet is pressed into the 118" Wheelbase 98 26
back of the cable mounting bracket. Apply lubricant All Other Models 132 35
to the rubber grommet (Fig. 119) on both sides of the Nominal refill capacities are shown. A variation may
cable mounting bracket. Work the rubber grommet be observed from vehicle to vehicle due to
(rearward) through the mounting bracket with two manufacturing tolerance and refill procedure.
small screwdrivers. Remove throttle cable from vehi
cle. FUEL SYSTEM PRESSURES—DIESEL ENGINES
IMSTALLATfOff
DESCRIPTION PRESSURE
(1) Feed the cable through the rear of its mounting
Fuel Pressure Drop Across Fuel
bracket (Fig. 119) until the rubber/plastic grommet
Filter . . . . . . . . . . . . . . . .35 kPa (5 psi) maximum
locks into position on the bracket.
(2) Connect cable end socket to the fuel injection Fuel Return Line or Component
pump lever ball (snaps on). Restriction (vacuum). . . .Approx. 100mm (4 in Hg)
(3) Install the remaining cable housing end into Fuel Transfer Pump
and through the dash panel opening (snaps into posi Pressure. Will vary.
tion). The two plastic pinch tabs (Fig. 118) should See manual text for procedures.
lock the cable to dash panel. Fuel Injector "pop off
(4) From inside the vehicle, hold up the accelera Pressure .3822 kPa (26,352 psi)
tor pedal. Install the throttle cable core wire and Maximum Injection Pump
plastic cable retainer into and through the upper end Pressure. .120,000 kPa (17,405)
of the pedal arm (the plastic retainer is snapped into
the pedal arm). When installing the plastic retainer
BR FUEL SYSTEM 14 -111
TORQUE—DIESEL ENGINES
DESCRIPTION TORQUE
Air-Fuel Control (AFC) Line
Fitting. . 24 N-m (18 ft. lbs.)
Banjo Fitting at top of
Filter/Separator. . . . . . . . . . . . .24 N-m (18 ft. lbs.)
Banjo Fitting at side of
Fuel Injector . . . . . . . . . . . . .8 N-m (6 ft. lbs.)
Banjo Fitting—-Fuel Supply Line at
side of Injector Pump . . . . . . . .24 N-m (18 ft. lbs.)
Engine Speed Sensor Nuts/Bolts. .24 N-m (18 ft. lbs.)
Fuel Drain Manifold Fitting Bolts
at Injectors 8 N-m (6 ft. lbs.)
Fuel Filter . . . . 1/2 Turn After Contact
Fuel Hose Clamps . . . . . . . . . . . . .1 N-m (15 in. lbs.)
Fuel Injector Retaining Nut . . . . .60 N-m (44 ft. lbs.)
Fuel Pump Module L o c k n u t . . . . .54 N-m (40 ft. lbs.)
Fuel Tank Mounting Nuts . . . . . .41 N-m (30 ft. lbs.)
Fuel Transfer Pump Mounting
Bolts . .24 N-m (18 ft. lbs.)
High-Pressure Fuel Line
F i t t i n g s ' . . . . . . . . . . . . . . . . . . .24 N-m (18 ft. lbs.)
High-Presure Fuel Line Fitting .
Clamps . . . . . . . . . . . . .6 N-m (4 ft. lbs.)
injector Pump Access Plug . . . . . .15 N-m (11 ft. lbs.)
injection Pump-to-injection
Pump Gear Nut . .165 N-m (122 ft. lbs.)
Injection Pump Mounting Nuts. . .24 N-m (18 ft. lbs.)
injection Pump Oil Fill Plug 28 N-m (21 ft. lbs.)
Intake Manifold Air Temp.
Sensor . . .28 N-m (20 ft. lbs.)
Intake Manifold Air Heater
Relay Bolts .4.5 N-m (40 in. lbs.)
Low-Pressure Bleed Bolt (Screw) . . .8 N-m (6 ft. lbs.)
14 -112 FUEL S Y S T E M
FUEL I N J E C T I O N S Y S T E M - D I E S E L EUGIME
INDEX
page page
GENERAL INFORMATION TRANSMISSION GOVERNOR PRESSURE

INTRODUCTION 112 SENSOR—PCM INPUT . . . . . . . . . . . . . . 118
DESCRIPTION AND OPERATION TRANSMISSION TEMPERATURE SENSOR—
AIR CONDITIONING (A/C) CONTROLS—PCM PCM INPUT . . . . . . . . . . . . . . . . . . . . . . 117
INPUT 114 TRANSMISSION TEMPERATURE WARNING
AIR CONDITIONING CLUTCH RELAY—PCM LAMP—PCM OUTPUT . 121
OUTPUT 119 VEHICLE SPEED SENSOR AND DISTANCE—
AUTOMATIC SHUTDOWN (ASD) RELAY—PCM PCM INPUT . . . . . . . . . . . . . . . . . . 118
OUTPUT 119 WAIT-TO-START LAMP WARNING LAMP—PCM
AUTOMATIC SHUTDOWN (ASD) SENSE—PCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
INPUT 114 WATER-IN-FUEL SENSOR—PCM INPUT . . . . . 119
BATTERY TEMPERATURE SENSOR—PCM WATER-IN-FUEL WARNING L A M P -
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 PCM INPUT 119
BATTERY VOLTAGE—PCM INPUT . . . . . . 114 DIAGNOSIS AND TESTING
BRAKE SWITCH—PCM INPUT . . . . . . . . . . . . . 114 AUTOMATIC SHUTDOWN (ASD) RELAY TEST . 123
DATA LINK CONNECTOR—PCM INPUT AND ENGINE SPEED SENSOR TEST 123
OUTPUT 120 INTAKE MANIFOLD AIR HEATER RELAY TEST . 125
' ENGINE SPEED SENSOR—PCM INPUT . . . . . 1 1 4 INTAKE MANIFOLD AIR HEATER TEST . . . . . . 124
GENERATOR FIELD—PCM OUTPUT . . . . . . . . 120 INTAKE MANIFOLD AIR TEMPERATURE
GENERATOR LAMP-PCM OUTPUT . 119 SENSOR TEST 123
, INTAKE MANIFOLD AIR HEATER RELAYS— THROTTLE POSITION SENSOR TEST . 126
PCM OUTPUT 116 TRANSMISSION TEMPERATURE SENSOR
INTAKE MANIFOLD AIR HEATER . . . . . . . . . . . 115 TEST . . . 126
INTAKE MANIFOLD AIR TEMPERATURE VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . 126
SENSOR—PCM INPUT . . . . . . . . . . . . . 114 VISUAL INSPECTION 121
MALFUNCTION INDICATOR LAMP—PCM REMOVAL AND INSTALLATION
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 AIR CLEANER HOUSING/AIR CLEANER
OVERDRIVE LAMP—PCM OUTPUT 120 ELEMENT . . . . . . ............. 129
OVERDRIVE/OVERRIDE SWITCH-PCM INPUT. 120 AUTOMATIC SHUTDOWN (ASD) RELAY . . . . . 126
PARK/NEUTRAL POSITION SWITCH—PCM ENGINE SPEED SENSOR 127
INPUT 117 INTAKE MANIFOLD AIR HEATER ELEMENTS . 130
POWERTRAIN CONTROL MODULE (PCM)— INTAKE MANIFOLD AIR HEATER RELAYS . . . . 131
DIESEL 113 INTAKE MANIFOLD AIR TEMPERATURE
SPEED CONTROL SOLENOIDS—PCM SENSOR 130
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 POWERTRAIN CONTROL MODULE 129
SPEED CONTROL SWITCH—PCM INPUT . . . . 117 THROTTLE POSITION SENSOR . . . . . . . . . . . 127
SYSTEM DIAGNOSIS . . . . . . . . . . . . . . . . 113 VEHICLE SPEED SENSOR 131
TACHOMETER—PCM OUTPUT 121 WATER-IN-FUEL SENSOR . . . . . 132
THROTTLE POSITION SENSOR—PCM INPUT . 1 1 7 SPECIFICATIONS
TORQUE CONVERTOR CLUTCH (TCC) ENGINE DATA PLATE SPECIFICATIONS 132
SOLENOID—PCM OUTPUT . . . . . . . . . . . . . 121 TORQUE SPECIFICATIONS—DIESEL . . . . . . . 132
GENERAL INFORMATION PCM for vehicles equipped w i t h diesel powered

engines.
INTRODUCTION Diesel fuel injection system components, except for
the intake manifold air heater elements, are not
Various components, relays and switches are oper
directly regulated by the PCM.
ated by the powertrain control module (PCM). This
Refer to the Fuel Delivery System—Diesel Engine
section of the group w i l l cover a description
section of this group for fuel components not oper-
and operation of components controlled by the
ated or regulated by the PCM. These components are
the:
• Fuel tank
• Fuel tank module
@ Low and high-pressure fuel supply lines
• Low-pressure, mechanical, fuel transfer pump
(fuel lift pump)
• High-pressure fuel injection pump
• Fuel filter/water separator
* • Fuel heater
• Fuel heater relay
• Fuel shutdown solenoid
• Fuel shutdown solenoid relay
• High-pressure fuel injectors
• Fuel return line
• Fuel filter (strainer)
® Fuel drain manifold Fig. 1 PCM Location
• Torque convertor engagement
DESCRIPTION AND OPERATION • ASD relay
® Air conditioning operation
SYSTEM DIAGNOSIS • Tachometer
The PCM can test many of its own input and out • Intake manifold air heater
put circuits. I f the PCM senses a fault in a major The PCM can adapt its programming to meet
system, the PCM stores a Diagnostic Trouble Code changing operating conditions.
(DTC) in memory. The PCM receives input signals from various
Technicians can display stored DTCs by two differ switches and sensors. Based on these inputs, the
ent methods. The first is to cycle the ignition switch PCM regulates various engine and vehicle operations
through different system components. These compo
On - Off - On - Off - On within 5 seconds. Then count
nents are referred to as PCM Outputs. The sensors
the number of times the malfunction indicator (check
and switches that provide inputs to the PCM are con
engine) lamp on the instrument panel flashes on and
sidered PCM Inputs.
off. The number of flashes represents the DTC. There
is a slight pause between the flashes representing NOTE: PCM Inputs:
the first and second digits of the code. Longer pauses
separate individual trouble codes. • Air conditioning selection
The second method of reading DTCs uses the DRB • Battery voltage
scan tool. For DTC information, refer to Group 25, • Brake light switch
Emission Control Systems. See On-Board Diagnos • Engine speed sensor (rpm)
tics. • Speed control switch position
© Auto shutdown (ASD) sense
POWERTRAIN CONTROL MODULE (PCM)—DIESEL
• Battery voltage input used to measure generator
The powertrain control module (PCM) is located in output
the right-rear side of the engine compartment (Fig. • Intake manifold air temperature sensor
1). I t is mounted to the dash panel cowl with three • Overdrive/override switch
bolts. The PCM was formerly referred to as the • Park/neutral switch (auto, trans, only)
SBEC or engine controller. Except for operation of • Power ground
the intake manifold air heater elements, the PCM ® SCI receive (DRB scan tool connection)
does not regulate or control fuel system operation on • Sensor return
the diesel engine. • Throttle position sensor (auto, trans, only)
The PCM is a pre-programmed, dual micro-proces • Transmission temperature sensor (auto, trans,
sor digital computer. Although i t does not regulate or only)
control the fuel system on the diesel powered engine, © Vehicle speed sensor
it does operate or regulate the: • Water-in-fuel sensor
• Speed control system • Ignition switch sense
• Charging system
• Certain warning lamps NOTE: PCM Outputs:
• Transmission overdrive solenoid
14 -114 FUEL SYSTEM BR
DESCRIPTION A N D OPERATION (Continued)
After inputs are received by the PCM, certain sen AUTOMATIC SHUTDOWN (ASD) SENSE—PCM
sors, switches and components are controlled or reg INPUT
ulated by the PCM. These are considered PCM A 12 volt signal at this input indicates to the PCM
Outputs. These outputs are for: that the ASD has been activated. The ASD relay is
• A/C clutch relay (A/C clutch operation) located in the power distribution center (PDC). The
• Auto shutdown (ASD) relay PDC is located in the engine compartment. For the
• Data link connectors (for DRB and MDS test location of the relay within the PDC, refer to PDC
equipment) cover.
• Generator field (charging system operation) This input is used only to sense that the ASD relay
• Malfunction indicator lamp (check engine lamp) is energized. I f the powertrain control module (PCM)
• Overdrive solenoid electrical operation (auto, does not see 12 volts + at this input when the ASD
trans, only) should be activated, i t will set a diagnostic trouble
• Overdrive/Override warning lamp (auto, trans, code (DTC).
only)
• SCI transmit (DRB scan tool connection) BATTERY VOLTAGE—PCM INPUT
• Speed control vacuum solenoid The battery voltage input provides power to the
• Speed control vent solenoid powertrain control module (PCM). I t also informs the
• Tachometer PCM what voltage level is being supplied by the gen
• Torque convertor electrical operation (auto, erator once the vehicle is running.
trans, only) The battery input also provides the voltage that is
• Transmission oil temperature warning lamp needed to keep the PCM memory alive. The memory
(auto, trans, only) stores diagnostic trouble code (DTC) messages, mini
• Wait-to-start lamp mum and maximum TPS value from the previous
• Water-in-fuel lamp key-on and speed control adaptive memory.
• Intake Manifold Air Heater Element #1
• Intake Manifold Air Heater Element #2 BATTERY TEMPERATURE SENSOR—PCM INPUT
Provides a signal to the PCM corresponding to the
AIR CONDITIONING (A/C) CONTROLS—PCM INPUT battery temperature. Refer to Group 8C, Charging
The A/C control system information applies to fac System for additional information.
tory installed air conditioning units.
A/C SELECT SIGNAL^ When the A/C switch is in BRAKE SWITCH—PCM INPUT
the ON position, an input signal is sent to the pow When the brake light switch is activated, the pow
ertrain control module (PCM). The signal informs the ertrain control module (PCM) receives an input indi
PCM that the A/C has been selected. The PCM cating that the brakes are being applied. After
adjusts idle speed to a pre-programmed rpm through receiving this input, the PCM is used to control the
the idle air control (IAC) motor to compensate for speed control system. I t is also used for electrical
increased engine load. operation of the transmission torque converter.
A/C BEQUEST SIGNAL: Once A/C has been
selected, the powertrain control module (PCM) ENGINE SPEED SENSOR—PCM INPUT
receives the A/C request signal from the evaporator The engine speed (rpm) sensor is mounted to the
switch. The input indicates that the evaporator tem front of engine (Fig. 2). I t generates an rpm signal to
perature is in the proper range for A/C application. the PCM. The engine speed sensor input is used
J
The PCM uses this input to cycle the A/C compressor along with the vehicle speed sensor and throttle posi
clutch (through the A/C relay). I t will also determine tion sensor (TPS) inputs to determine when to shift
the correct engine idle speed through the idle air con the automatic transmission into and out of overdrive.
trol (IAC) motor position. The speed sensor signal is also used as an input for
If the A/C low-pressure switch opens (indicating a the ASD relay (for control of generator field), vehicle
low refrigerant level), the PCM will not receive an speed control, torque convertor electrical engagement
A/C receive signal. The PCM will then remove the and instrument panel mounted tachometer.
ground from the A/C relay. This will deactivate the
A/C compressor clutch. INTAKE MANIFOLD AIR TEMPERATURE SENSOR—
If the evaporator switch opens, (indicating that
PCM INPUT
evaporator is not in proper temperature range), the
The intake manifold air temperature sensor is a
PCM will not receive the A/C request signal. The
variable, thermistor type. I t reacts to temperature
PCM will then remove the ground from the A/C relay,
deactivating the A/C compressor clutch. changes. At cold air temperatures, its resistance is
FUEL SYSTEM 14 - 115
D E S C R I P T I O N AMD O P E R A T I O N ( C o n t i n u e d !
SENSOR MOUNTING BOLTS FRONT OF ENGINE AIR TEMPERATURE SENSOR

SENSOR ELECTRICAL
CONNECTOR
INTAKE
MANIFOLD
FUEL
(UPPER HALF) SOLENOID
SHUTDOWN
VIBRATION SOLENOID ELECTRICAL
J9414-93
J9214-69 CONNECTOR
DAMPER
Fig. 2 Engine Speed Sensor—Diesei Fig. 3 Air Temperature Sensor Location—Diesei
high. As temperatures increase, its resistance will AIR CABLE INTAKE MANIFOLD
HEATER NUTS (2) BOLTS (5)
decrease. ASSEMBLY
The air temperature sensor element extends into
the intake manifold air stream. I t provides an input
voltage to the PCM indicating intake manifold air LOWER PART
OF INTAKE
temperature. The input from this sensor is used by MANIFOLD
the PCM to determine i f and how long to activate the
intake manifold air heater relays. When the relays
CABLE
are activated, current will flow through the relays to MOUNTING
the intake manifold air heater element. STUDS (2)
As the temperature of the air-fuel stream in the
manifold varies, the sensor resistance will change.
This will result in a different input voltage to the
PCM.
The sensor is located on the top of the intake man
ifold and to the rear of the intake manifold air heater
(Fig. 3).
Also refer to Intake Manifold Air Heater Relays for
additional information.
INTAKE MANIFOLD AIR HEATER

The intake manifold air heater element assembly
is located in the top of the intake manifold (Fig. 4).
The air heater is used to heat incoming air to the DIPSTICK TUBE
intake manifold to help engine starting and improve BOLT
driveability with cool or cold outside temperatures. UPPER PART OF
Two heavy-duty cables (Fig. 5) connect the 2 air
heater elements to the 2 air heater relays. Each of
these cables will supply approximately 95 amps at 12 Fig. 4 Air Heater Location
volts to an individual heating element within the (PCM) through the 2 air heater relays. Refer to
heater block assembly. Intake Manifold Air Heater Relays for more informa
Electrical supply for the 2 air heater elements (Fig. tion.
5) is controlled by the powertrain control module
DESCRIPTION AND OPERATION {Continued)
AIR INTAKE The powertrain control module (POM) operates the
HEATER POWER 2 heating elements within the air heater assembly
GASKET SUPPLY LINES through the 2 intake manifold air heater relays. The
air heater elements are used to heat incoming air
flowing into the intake manifold. This will help
engine starting and improve driveability with cool or
cold outside temperatures.
The relays may be energized by the POM before
and after cranking. This will depend on inputs the
PCM receives from: the intake manifold air tempera
ture sensor, the engine speed sensor and the vehicle
speed sensor.
With a cool or cold engine, the air heater relays
and the air heater elements may be activated for a
maximum time of approximately 3 1/2 minutes. Refer
to the following Air Heater Cycle Chart for a temper
ature/time comparison of relay engagement.
In this chart, Pre-Heat and Post-Heat times are
mentioned. Pre-heat is the amount of time the relay
circuits are activated when the ignition (key) switch
is ON, but the engine has yet to be started. Post-heat
is the amount of time the relay circuits are activated
after the engine is operating.
The wait-to-start warning lamp is tied to this cir
INTAKE
cuit. Lamp operation is also controlled by the PCM.
The wait-to-start warning lamp w i l l not be illumi
nated during the post-heat cycle.
Fig. 5 Air Heater Elements
The relays are not energized during engine crank
INTAKE MANIFOLD AIR HEATER RELAYS—PCI ing. When initially energized, they will make a click
OUTPUT ing noise.
The 2 relays are located in the engine compart
PREHEAT CYCLE
ment below the left battery (Fig. 6).
The PCM will supply a signal to the 2 relays when
BATTERY the ignition (key) switch is initially turned to the ON
(LEFT SIDE) position. When this signal is supplied, electrical cur
rent is passed through the relays for operation of the
2 heating elements.
If the intake manifold air temperature is 15°C
(59°F) or below, the air heater elements are ener
gized and the wait-to-start warning lamp is illumi
nated. The heater is energized for a specific amount
of time. Refer to the following Air Heater Cycle Chart
(Fig. 7) for a temperature/time comparison of relay
engagement.
Once the heater has cycled, the wait-to-start warn
ing lamp goes out.
While the engine is cranked, the heater relays are
not energized.
POST-HEAT CYCLE
After the pre-heat cycle is completed, the PCM
must receive an engine crank signal (engine speed
between 32 and 475 rpm) followed by an engine run
signal (engine speed above 475 rpm). Intake manifold
air temperature must also be below 15°C (59°F). All
Fig, 6 intake Manifold Air Heater Relays of these signals must be seen by the PCM before ini
tiating the post-heat cycle.
en FUEL SYSTEM 14 - 117
DESCRIPTION AND O P E R A T I O N fContinued)

Depending upon intake manifold air temperature, switch feature has been selected. The three switches
engine rpm and predetermined PCM values, one or are: On/Off, Set/Coast and Resume/Accelerate.
both of the relays and one or both of the heating ele The speed control operating range is from approx
ments may be activated. This may be observed as a imately 56 km/h to 137 km/h (35 to 85 mph). Inputs
large needle swing on the vehicle voltmeter and is that effect speed control operation are:
due to the high-amperage draw of the heating ele • Brake switch position
ments. Each heating element will draw approxi • Park/neutral switch
mately 95 amps at 12 volts. This voltmeter • Vehicle speed sensor
movement is a normal condition during the • Engine speed sensor
post-heat cycle. • Throttle position sensor (auto, trans, only)
Refer to the following Air Heater Cycle Chart (Fig. Refer to Group 8H for further speed control infor
7) for a temperature/time comparison of relay mation.
engagement.
The PCM is also programmed with battery saving PARK/NEUTRAL POSITION SWITCH—PCM INPUT
features. I t will shut down the air heater relays if: The park/neutral switch provides an input to the
• the engine starter is operated during the pre powertrain control module (PCM). This will indicate
heat cycle. that the automatic transmission is in Park, Neutral
• the engine stalls during the post-heat cycle. or a Drive gear selection. This input is used to deter
• the engine starter is operated for more than 10 mine speed control strategy and electrical operation
seconds during the post-heat cycle. of both the overdrive and torque convertor solenoids.
• the vehicle speed is above 10 mph during the Refer to Group 21, Transmissions, for testing,
post-heat cycle. replacement and adjustment information.
The post-heat cycle will continue for up to 3 1/2
minutes unless the PCM determines one or more of THROTTLE POSITION SENSOR—PCM INPUT
these preceding features interrupts the cycle strat The throttle position sensor (TPS) is used only on
egy. vehicles equipped with an automatic transmission i f
equipped with a diesel engine. I t is not used with the
PK4€1T€¥QI11IE manual transmission.
lEimRAIURE- «Nm0N0liB«MI BNmONONr The TPS is mounted on the side of the fuel injec
^ ^ ^ ^ tion pump (Fig. 8). The TPS provides an input to the
Above 15°C 0 seconds No PCM. I t senses how far the throttle is open (past the
(59° F) idle position). The PCM uses the TPS input, along
with vehicle speed sensor and engine speed sensor
-10°Cto 15° C 10 seconds Yes inputs to determine 3-4 upshift (overdrive) and 4-3
(15° F to 59° F)
downshift. I t is also used with the vehicle speed sen
-18° C to -10° F 15 seconds Yss sor and engine speed sensor inputs to engage and
(0° Fto 15° F) disengage the torque convertor solenoid. This sole
noid is used for torque convertor engagement.
Below-18° C 30 seconds Yes
The TPS is a linear potentiometer. The PCM sup
(0° F)
plies 5 volts to the sensor. TPS output voltage to the
J9414-133 PCM will vary. At idle speed, the voltage should be
1.0 volt (± .2 volts). At wide open throttle (WOT), the
output voltage must be 2.2-to-2.9 volts higher than at
idle speed.
TRANSMISSION TEMPERATURE SENSOR—PCM

INPUT
DIESEL WITH AUTOMATIC TRANSMISSIONS

Fig. 7 Air Heater Cycle Chart
ONLY
SPEED CONTROL SWITCH—PCM INPUT The transmission temperature sensor is a variable,
Six different speed control functions, using three thermistor type. I t reacts to temperature changes. At
momentary contact switches, are monitored through cold transmission oil temperatures, its resistance is
this multiplexed input. The resistance monitored at high. As temperatures increase, its resistance will
this input, in combination with the length of time the decrease.
PCM measures the resistance, determines which
14 - 118 FUEL SYSTEM — — — mm
DESCRIPTION mm OPERATION (Continued)
TRANSMISSION GOVERNOR PRESSURE
SENSOR—PCM INPUT
Provides a signal proportional to the transmission
governor pressure. I t provides feedback for control of
the variable force solenoid, which regulates transmis
sion governor pressure. This input is used with
4-speed electronic transmissions only.
VEHICLE SPEED SENSOR AND DISTANCE—PCM

INPUT
The speed sensor (Fig. 10) is located in the exten
sion housing of the transmission (2WD) or on the
transfer case extension housing (4WD). The sensor
input is used by the powertrain control module
(PCM) to determine vehicle speed and distance trav
eled.
The speed sensor generates 8 pulses per sensor
revolution. These signals, in conjunction with a
closed throttle signal from the throttle position sen
b U L , i
sor (auto, trans, only), indicate a closed throttle
IS OUTPUT WIRE > U) J94U-91
deceleration to the PCM. When the vehicle is stopped
at idle, a closed throttle signal is received by the
F/g. 0 Throttle Position Sensor Location—Diesei PCM (but a speed sensor signal is not received).
The transmission temperature sensor is used on In addition to determining distance and vehicle
models equipped with an automatic transmission. Its speed, the output from the sensor is used to help con
purpose is to help control transmission fluid over trol:
heating, i f transmission overheating has been deter • Speed control operation
mined by this sensor (temp, above approximately 280 • Transmission overdrive operation
degrees F), an input is sent to the powertrain control • Transmission torque converter electrical opera
module (PCM). The PCM will then force a 4-3 down tion
shift. Once transmission temperature has cooled
below specifications, a 3-4 upshift will be allowed. An SENSOR
instrument panel mounted transmission temperature ELECTRICAL
CONNECTOR
warning lamp is also used.
This sensor is located in the transmission cooling
line on the side of the transmission (Fig. 9).
J9414-60
TEMPERATURE SENSOR ' J9414-46
Fig. 9 transmission Temperature Sensor Location— Fig. 10 Vehicle Speed Sensor—Typical

Typical

WATER-IN-FUEL SENSOR—PCM INPUT the input at the end of the intake manifold air heater
The water-in-fuel (WIF) sensor is located at the post-heat cycle.
bottom of the fuel filter/water separator (Fig. 11).
WATER-IN-FUEL WARNING LAMP—PCM INPUT
FUEL FILTER/
The PCM turns the water-in-fuel indicator lamp to
WATER SEPARATOR the ON position i f water is detected in the fuel. The
water-in-fuel indicator lamp is located i n the instru
ment panel (Fig. 12). The lamp will illuminate for
about two seconds each time the ignition key is ini
tially turned to the ON position as a bulb check.
Also refer to Water-In-Fuel Sensor—PCM Input for
additional information.
DRAIN AIR CONDITIONING CLUTCH RELAY—PCM

WATER-IN- VALVE
FUEL SENSOR OUTPUT
The A/C relay is located in the Power Distribution
J9414-90 for relay location.
The powertrain control module (PCM) activates the
A/C compressor through the A/C clutch relay. The
Fig, 11 Water-in-Fuel Sensor
PCM regulates A/C compressor operation by switch
WAIT-TO- ing the ground circuit for the A/C clutch relay on and
START off.
W A R N I N G LAMP
The PCM will also de-energize the relay i f coolant
temperature exceeds 125°C (257°F).
POWER
DISTRIBUTION
CENTER
(PDC)
HEAT-A/C
TEMPERATURE
CONTROL
KNOB
TRANSMISSION J9414-10
WATER-IN-FUEL TEMPERATURE
W A R N I N G LAMP W A R N I N G LAMP J9414-63
Fig. 13 Power Distribution Center (PDC) Location
Fig. 12 Wait-to-Start and Water-in-Fuel Warning AUTOMATIC SHUTDOWN (ASD) RELAY—PCM
Lamp Location OUTPUT
The sensor sends an input to the powertrain con This circuit controls operation of the ASD relay. I t
trol module (PCM) when it senses water i n the fuel provides the necessary power to operate the genera
filter/water separator. As the water level in the filter/ tor field control for charging system operation.
separator increases, the resistance across the WIF The ASD relay is located in the power distribution
sensor decreases. This decrease in resistance is sent center (PDC). The PDC is located in the engine com
as a signal to the PCM and compared to a high water partment. For location of relay within the PDC, refer
standard value. Once the value reaches 30 to 40 kilo- to PDC cover.
hms, the PCM will activate the instrument panel
mounted, water-in-fuel warning lamp (Fig. 12). This GENERATOR LAMP-PCM OUTPUT
all takes place when the ignition key is initially put If the powertrain control module (PCM) senses a
in the ON position. The PCM continues to monitor low charging condition i n the charging system, i t will
illuminate the generator lamp (if equipped) on the

instrument panel. For example, during low idle with
all accessories turned on, the lamp may momentarily
go on. Refer to Groups 8A and 8C for charging sys
tem information.
GENERATOR FIELD—PCM OUTPUT

The powertrain control module (PCM) regulates
the charging system voltage within a range of 12.9 to
15.0 volts. Refer to Groups 8A and 8C for charging
system information.
DATA LINK CONNECTOR—PCM INPUT AND

OUTPUT
The 16-way data link connector (diagnostic scan
tool connector) links the Diagnostic Readout Box
(DRB) scan tool or the Mopar Diagnostic System Fig. 15 Check Engine Lamp—Typical Location
(MDS) with the powertrain control module (PCM). On-Off-On within three seconds and any codes stored
The data link connector (Fig. 14) is located at lower in the PCM memory will be displayed. This is done
edge of instrument panel near steering column. For in a series of flashes representing digits. Refer to On-
operation of the DRB scan tool, refer to the appropri Board Diagnostics i n the General Diagnosis section
ate Powertrain Diagnostic Procedures service man of this group for more information.
ual.
16-WAY DATA OVERDRIVE LAMP—PCM OUTPUT
LINK CONNECTOR This circuit controls a signal for the operation of
the instrument panel mounted push-button overdrive
lamp switch. When the lamp is illuminated, the over
drive is disengaged.
OVERDRIVE/OVERRIDE SWITCH-PCM INPUT

On vehicles equipped with an automatic transmis
sion and overdrive, the powertrain control module
(PCM) regulates the 3-4 overdrive up-shift and down
shift through the overdrive solenoid. This solenoid is
located in the transmission. An overdrive/override
push-button switch is located on the instrument
panel.
805dd852
The PCM circuit for overdrive is controlled by
inputs from the engine coolant temperature sensor
Fig. 14 16-Way Data Link Connector and vehicle speed sensor. I f coolant temperature and
vehicle speed are not within the preset PCM specifi
MALFUNCTION INDICATOR LAMP—PCM OUTPUT
cations, the PCM will not allow the transmission to
The malfunction indicator lamp illuminates on the shift into overdrive. These preset PCM specifications
instrument panel each time the ignition key is must be met before the push-button switch will be
turned on. This lamp is displayed on the instrument allowed to control overdrive operation.
panel as the CHECK ENGINE lamp (Fig. 15). Note The overdrive/override push-button switch is nor
that the lamp will illuminate for approximately two mally closed (overdrive allowed) when the lamp is
seconds each time the key is initially turned to the not illuminated. I t opens (overdrive not allowed)
ON position. This feature is used as a bulb check. when the operator presses the switch and the lamp is
If the powertrain control module (PCM) receives an illuminated. The switch will revert to its normally
incorrect signal, or no signal from certain sensors or closed position (lamp off) each time the ignition
components, the lamp is turned on. This is a warning switch in turned on. The transmission downshifts i f
that the PCM has recorded a system or sensor mal the operator presses the override switch while in
function. I t signals an immediate need for service. overdrive.
The lamp can also be used to display a diagnostic Refer to Group 21 for more transmission informa
trouble code (DTC). Cycle the ignition switch On-Off- tion.
SPEED CONTROL SOLENOIDS—PCM OUTPUT This feature is used with certain heavy-duty auto
Speed control operation is regulated by the power- matic transmissions only.
train control module (PCM). The PCM controls the Also refer to Transmission Temperature Sensor—
vacuum to the throttle actuator through the speed PCM Input for additional information.
control vacuum and vent solenoids. Refer to Group INSTRUMENT
8H for Speed Control Information.
TACHOMETER—PCM OUTPUT
The powertrain control module (PCM) supplies
engine rpm values to the instrument cluster tachom
eter. Refer to Group 8E for tachometer information.
TORQUE CONVERTOR CLUTCH (TCC) SOLENOID—

PCM OUTPUT
AUTOMATIC TRANSMISSION ONLY
TORQUE CONVERTER CLUTCH

AND OVERDRIVE SOLENOID
ELECTRICAL CONNECTOR
Fig. 17 Transmission Temperature Warning

Lamp—Typical Location
WAIT-TO-START LAMP WARNING LAMP—PCM
OUTPUT
The wait-to-start warning lamp is turned on and
off by the PCM based on the intake manifold air tem
perature sensor input. The lamp is located on the
instrument panel.
VEHICLE The lamp is turned on when the ignition is first
SPEED
SENSOR J9414-59 activated. I f the PCM reads intake manifold air tem
perature below 15°C (59°F), i t will turn the wait-to-
Fig. 16 Eiectrical Connections at Transmission—
start warning lamp on for the air heater preheat
cycle. The lamp stays on until the preheat cycle is
TCC and Overdrive Solenoids
over.
The powertrain control module (PCM) will deter The wait-to-start lamp will flash on and off i f the
mine when to engage and disengage the solenoid by intake manifold air temperature sensor input to the
monitoring vehicle miles per hour (mph). Also needed PCM is below minimum value or above maximum
are various inputs from the module timer, engine value. The PCM stores a DTC when these conditions
rpm and throttle position sensor. occur.
Refer to Intake Manifold Air Heater for additional
TRANSMISSION TEMPERATURE WARNING • information.
LAMP—PCM OUTPUT
AUTOMATIC TRANSMISSION ONLY DIAGNOSIS AND T E S T I N G

An instrument panel mounted lamp (Fig. 17) is
:
used to warn of a possible transmission fluid over VISUAL INSPECTION .
heating condition. When transmission fluid tempera A visual inspection for loose, disconnected, or incor
ture has been determined to be above approximately rectly routed wires and hoses should be made before
280 degrees F by the transmission temperature sen attempting to diagnose or service the diesel fuel
sor, a signal is sent to the powertrain control module injection system. A visual check will help find these
(PCM). The PCM will then control warning lamp conditions. I t also saves unnecessary test and diag
operation. The lamp will illuminate for about two nostic time. A thorough visual inspection of the fuel
seconds each time the ignition key is initially turned injection system includes the following checks:
to the ON position as a bulb check. (1) Be sure that the battery connections (on both
batteries) are tight and not corroded.
14-122 FUEL SYSTEM
DIAGNOSIS A N DTESTING (Continued)
(2) Be sure that the three 32-way connectors are FRONT OF ENGINE AIR TEMPERATURE SENSOR
fully engaged into the powertrain control module SENSOR ELECTRICAL
(PCM) (Fig. 18). CONNECTOR
' POWERTRAIN
CONTROL MODULE
(PCM)
INTAKE
8056d9f8
MANIFOLD p u E L

Fig. 18 PCM Location—Typical SOLENOID ELECTRICAL
J9414-93
CONNECTOR
(3) Be sure that the electrical connections at the
intake manifold air heater relays (Fig. 19) are tight Fig. 20 Air Temperature Sensor and Fuel Shutdown
and not corroded. Solenoid
BATTERY 21). Inspect the connector for corrosion or damaged

(LEFT SIDE) wires.
CABLES TO
BATTERY (+) FILTER
w
FUEL FILTER/ -
\ , \ f|HOUSlNG WATER SEPARATOR
INTAKE AIR
HEATER RELAYS (2)
ELECTRICAL / V
CONNECTOR J9414-87
RELAY Fig. 21 WateNn-Fuel (WIF) Sensor

TRIGGER RELAY MOUNTING >
WIRES (4) BOLTS (3) J9414-85 (7) Check for water in the fuel filter/water separa
tor. A water drain is supplied on the filter/separator.
Fig. 19 Intake Manifold Air Heater Relays Refer to Fuel Filter/Water Separator in the Diesel
Engine—Component Removal/Installation section of
(4) Inspect the starter motor and starter solenoid
this group for draining water.
connections for tightness and corrosion.
(8) Verify that the electrical connector is firmly
(5) Verify that the electrical connector is firmly
connected to the fuel shutdown solenoid on the injec
connected to the intake manifold air temperature
tion pump (Fig. 20). Inspect the connector for corro
sensor. Inspect the connector for corrosion or dam
sion or damage.
aged wires. The sensor is located on the top of the
intake manifold (Fig. 20).
(6) Verify that t h e water-in-fuel (WIF) sensor elec
trical connector is firmly attached to the sensor (Fig.

(9) Be sure that the intake manifold air heater (18) Automatic Transmission Only: Raise the vehi
electrical cable connections at the intake manifold cle and check the electrical connection at the trans
are tight and free of corrosion (Fig. 22). mission temperature sensor (Fig. 23).
TEMPERATURE SENSOR J9414-46
Fig. 23 Transmission Temperature Sensor

Location—Typical
(19) Automatic Transmission Only: Be sure the
electrical connector is firmly connected to the plug
leading to the overdrive solenoid in the transmission.
AUTOMATIC SHUTDOWN (ASD) RELAY TEST

To perform a complete test of the ASD relay and its
circuitry, refer to the DRB scan tool and appropriate
UPPER PART OF Powertrain Diagnostics Procedures manual. To test
the relay only, refer to Relays—Operation/Testing in
this section of the group.
Fig. 22 Air Heater Cable Connections
(10) Inspect the throttle linkage and accelerator ENGINE SPEED SENSOR TEST
linkage for binding. To perform a complete test of this sensor and its
(11) Be sure that the throttle return spring is con circuitry, refer to the appropriate Powertrain Diag
nected. nostic Procedures manual.
(12) Inspect all fuel supply and return lines for
signs of leakage. INTAKE MANIFOLD AIR TEMPERATURE SENSOR
(13) Be sure that the ground connections are tight TEST
and free of corrosion. Refer to Group 8, Wiring for To perform a complete test of this sensor and its
locations of ground connections. circuitry, refer to DRB scan tool and appropriate
(14) Inspect the air cleaner element (filter) for Powertrain Diagnostics Procedures manual. To test
restrictions by using the built-on Filter Minder®. Do the sensor only, refer to the following:
not remove the top of air cleaner housing to inspect (1) Disconnect the wire harness connector from the
condition of air cleaner element. Refer to Diesel intake manifold air temperature sensor. The sensor
Engine Component Removal/Installation section for is located on the top of the intake manifold and to
Filter Minder information. the rear of the air heater (Fig. 24).
(15) Be sure that the turbocharger output hose is (2) Test the resistance of the sensor with an input
connected to the charge air cooler (intercooler) inlet impedance (digital) volt-ohmmeter. The resistance (as
tube. Verify that the charge air cooler output hose is measured across the sensor terminals) should be less
connected to the cooler and the intake manifold. than 1340 ohms with the engine warm. Refer to the
(16) Be sure that the vacuum pump-to-brake Sensor Resistance (OHMS)—Intake Manifold Air
booster hose is connected and not damaged. Temperature resistance chart (Fig. 25). Replace the
(17) Be sure that the accessory drive belt is not sensor i f i t is not within the range of resistance spec
damaged or slipping. ified in the chart.
14 - 124 FUEL SYSTEM en
1AGNOS9S AND TESTING ( C o n t i n u e d )
FRONT OF ENGINE AIR TEMPERATURE SENSOR INTAKE MANIFOLD AIR HEATER TEST
SENSOR ELECTRICAL The intake manifold air heater (Fig. 26) is con
CONNECTOR
trolled by the powertrain control module (PCM)
through the intake manifold air heater relays (Fig.
27). This is done after a specified signal is sent to the
PCM from the intake manifold air temperature sen
sor.
Two heating elements are located within the air
heater assembly. A separate heavy-duty cable is con
nected to a separate terminal to supply power for
each element.
AIR CAILE INTAKE MANIFOLD
HEATER NUTS (21 BOLTS (5)
ASSEMBLY
LOWER PART
OF INTAKE
INTAKE MANIFOLD
MANIFOLD CABLES (2)
(UPPER HALF) ' rx)WN
SHU T SOLENOID'
SOLENOID ELECTRICAL .9414.90 CABLE
CONNECTOR J V 4 1 4 V J
MOUNTING
STUDS (2)
Fig. 24 Air Temperature Sensor LocaHon—-Diesei
TEMPERATURE RESISTANCE (OHMS)
C F mm HAJC
-40 -40 291,490 381710

-20 -4 85,850 108,390
-10 14 49,250 61,430
0 32 29,330 35,990
10 50 17,990 21,810
20 68 11,370 13,610
25 77 9,120 10,880
30 86 7,370 8,750
40 104 4,900 5,750 DIPSTICK TUBE
50 122 3,330 3,880 BOLT
60 140 2,310 2,670 UPPER PART OF
70 158 1,630 1,870
80 176 1,170 1,340
90 194 860 970 Fig. 26 Intake Manifold Air Heater
100 212 640 720
no 230 480 540 PfRBHEAT/POST-HEAT CYCLE
120 248 370 410 Refer to the Intake Manifold Air Heater Relays-—
PCM Output for preheat/post heat cycle information.
J928D-4 The PCM provides a ground path for the intake
manifold air heater relays. The ground path is pro
Fig. 25 SENSOR RESISTANCE (OHMS)—INTAKE vided i f intake manifold air temperature is 15°C
MANIFOLD AIR TEMPERATURE SENSOR (59°F) when the ignition key is initially placed in the
(3) Test the resistance of the wire harness. Do this ON position. When the ground is provided, the air
between the powertrain control module (PCM) wire heater is energized to start the preheat cycle.
harness connector terminal A-15 and the sensor con The preheat-cycle can be tested with a voltmeter or
nector terminal. Also check between PCM terminal test light. I f the intake manifold air temperature is
A-4 (sensor return) to the sensor connector terminal. above 15°C (59°F), the wait-to-start warning * lamp
Repair the wire harness as necessary i f the resis will not illuminate and the air heater will not be
tance is greater than 1 ohm. energized.
DIAGNOSIS A N DTESTING fContinued)

BATTERY
HEATER TEST
(LEFT SIDE) (1) Disconnect both negative battery cables at both
batteries.
(2) Lift the rubber shields from each of the cable
connectors at the intake manifold air heater (Fig. 26)
to expose the cable terminals. Do not disconnect
cable nuts.
(3) Use an ohmmeter to test the resistance
between the cable terminal (not the mounting stud)
and a ground. The resistance should be zero (0). I f
not, inspect for corroded or dirty cable connections.
Clean or repair the connections and retest before
replacing heater. I f resistance is now anything other
than zero (0), proceed to next step.
(4) Disconnect both cables from the intake mani
fold heater (two nuts) (Fig. 26).
(5) Measure the resistance from each of the air
heater terminal threaded studs to a ground. The
resistance should be zero (0). I f the ohmmeter is still
reading anything other than zero (0), replace the
intake manifold air heater elements. The heater ele
ments are part of the intake manifold and will
Fig. 27 intake Manifold Mir Heater Relays require manifold replacement.
(6) After testing and repairing, connect battery
(1) With the engine not running and ambient air
cables to both batteries.
temperature below 15°C (59°F), turn the ignition key-
to the ON position.
INTAKE MANIFOLD AIR HEATER RELAY TEST
(2) The wait-to-start warning lamp will come on
To test the intake manifold air heater, refer to the
and the air heater relays should click ON signaling
previous Intake Manifold Air Heater Test.
the start of the preheat cycle. If the engine starter
To test the intake manifold air heater relays, refer
is engaged before the preheat cycle of the heat
to the following:
ers is complete, the P C M will stop the remain
ing preheat cycle.
batteries.
(3) Check for battery voltage at both air heater
(2) Disconnect the four small relay trigger wires at
terminals (Fig. 26). The heater will only be ener
both relays (Fig. 27). Note position of wires before
gized for 10 to 30 seconds. Refer to the following
removal.
Air Heater Cycle Chart (Fig. 28) for a time/tempera
(3) Disconnect the four large cables at each of the
ture comparison. .
relay terminals (four nuts) (Fig. 27). Note position of
^ ^ ^ ^ ^ MS4CATCYCU1IME
cables before removal.
wmmmm -BNmONOHrMME KMIKMON, (4) Attach an ohmmeter across two of the large
mmmmm ^ ^ ^ ^ studs on one of the relays.
(5) Attach a jumper wire (+ and -) to each of the
Above 15°C 0 seconds No small terminals on one of the relays. Polarity is not
(59° F)
important.
-10°Cto 15° C 10 seconds Yes (6) Momentarily touch the jumper wires to the
(15° F to 59° F) vehicle battery (+ and -). The relay should click and
the ohmmeter should show a closed circuit across the
-18° C to-10° F 15 seconds Yes large terminals. I f not, replace relay and bracket
(0° F to 15° F)
assembly.
Below-18° C 30 seconds Yes (7) Repeat the same test on the opposite relay.
(0° F) (8) After testing and repairing, connect battery
cables to both batteries.
J9414-133
Fig. 28 AIR HEATER CYCLE CHART

P I & G I T O S I S AiND T E S T I N G (Continued)
THROTTLE POSITION SENSOR TEST

The throttle position sensor (TPS) is used on diesel TEMPERATURE RESISTANCE (OHMS)
engines only when equipped with an automatic
transmission. C F mm MAX
Refer to Throttle Position Sensor in the Component
Removal/Installation section. This will give adjust -40 291,490 381,710
ment, testing and removal/installation procedures. -20 -4 85,850 108,390
-10 14 49,250 61,430
0 32 29,330 35,990
TRANSMISSION TEMPERATURE SENSOR TEST 10 50 17,990 21,810
20 68 11,370 13,610
AUTOMATIC TRANSMISSION omiw 25 77 9,120 10,880
To perform a complete test of this sensor and its 30 86 7,370 8,750
40 104 4,900 5,750
50 122 3,330 3,880
Powertrain Diagnostics Procedures manual. To test 60 140 2,310 2,670
the sensor only, refer to the following: 70 158 1,630 1,870
(1) Disconnect the wire harness connector from the 80 176 1,170 1,340
temperature sensor. The sensor is located on the side 90 194 860 970
of the transmission in the transmission cooling line 100 212 640 720
(Fig.29). no
120
230
248
480
370
540
410
J928D-4
Fig. 30 SENSOR RESISTANCE (OHMS)—

TRANSMISSION TEMPERATURE SENSOR
To perform a complete test of the sensor and its
REMOVAL A N E INSTALLATION
AUTOMATIC SHUTDOWN (ASD) RELAY

TEMPERATURE S E N S O R J9414-46 The ASD relay is located in the Power Distribution
Fig, 29 Transmission Temperature Sensor for relay location. Check terminal connections at
Location—Typical PDC and relay for damage/corrosion before installa
(2) Test the resistance of the sensor with an input tion. Repair as necessary.
impedance (digital) volt-ohmmeter. The resistance (as
measured across the sensor terminals) should be less
than 1340 ohms with the engine warm. Refer to the
Sensor Resistance (OHMS)—Transmission Tempera
ture Sensor resistance chart (Fig. 30). Replace the
sensor i f it is not within the range of resistance spec
ified in the chart.
(3) Test the resistance of the wire harness. Do this
between the powertrain control module (PCM) wire
harness connector terminal B - l and the sensor con
nector terminal. Also check between PCM terminal
A-4 to the sensor connector terminal. Repair the
wire harness as necessary i f the resistance is greater
than 1 ohm.

BR FUEL S Y S T E M 14 - 127

ENGINE SPEED SENSOR
The engine speed (rpm) sensor is located on the
front of engine (Fig. 32). Spacers located behind the
sensor are used to position sensor over the vibration
damper.
SENSOR MOUNTING BOLTS
ST, "
Fig. 33 Engine Speed Sensor—Installation

(3) Place the feeler gauge between the sensor and
the vibration dampener.
(4) Gently seat (push down) the sensor until it con
tacts the feeler gauge. Be sure the sensor is not
near either of the notches (Fig. 32) on the
vibration damper. If sensor is adjusted at or
near these notches, it will be damaged when
engine is started.
VIBRATION (5) Tighten sensor mounting nuts to 24 N-m (18 ft.
DAMPER J9214-69
lbs.) torque.
Fig. 32 Engine Speed Sensor—Diesel (6) Remove feeler gauge.
(7) Connect the sensor electrical connector to the
REMOVAL main engine wiring harness.
Before removing the sensor, note the position and
routing of the sensor wiring harness. This routing THROTTLE POSITION SENSOR
must be maintained to prevent wiring from contact
ing belt or pulleys. AUTOMATIC TRANSMISSION ONLY
(1) Disconnect the speed sensor pigtail harness The throttle position sensor (TPS) is used on
from the main engine wiring harness near the front/ the diesel powered engine only when equipped
top of engine. with an automatic transmission. If the TPS is to
(2) Remove the clip bolts from the sensor pigtail be replaced on a diesel engine, it must be test
wiring harness. ed/adjusted after replacement.
(3) Remove the two speed sensor mounting nuts
(Fig. 32). REMOVAL
(4) Remove the speed sensor and its mounting (1) Disconnect the electrical connector on bottom of
spacers from the vehicle. TPS (Fig. 34).
(2) Remove the two TPS mounting bolts.
INSTALLATION/ADJUSTMENT (3) Remove the sensor from bracket.
The engine speed sensor uses a slotted hole on one
side (Fig. 33) to adjust its depth. A brass (non-mag INSTALLATION
netic) feeler gauge must be used to adjust the sensor. (1) Position the TPS to the mounting bracket. The
Sensor-to-vibration damper air gap is: 1.25 M M electrical connector should be facing downward.
(.049 in.) minimum to 1.30 MM (.051 in.) maximum.
(1) Position speed sensor, its mounting spacers and NOTE: The TPS is spring loaded. After positioning
two mounting nuts to the engine. Install mounting the TPS to its mounting bracket, rotate the TPS on
nuts finger tight. the bracket in a counterclockwise direction until the
(2) Route sensor wiring harness behind engine pul two bolt holes align.
leys. Install and tighten wiring harness clip bolts.
(2) Install and tighten two bolts.
REUOWAL AND INSTALLATION (Continued!
B O U 5
IS OUTPUT WIRE J9414-91
Fig. 34 Throttle Position Sensor—Diesel

(3) Connect the electrical connector on bottom of
TPS.
(4) Operate the throttle by hand to check for bind CENTER REAR FACE
OF BALL OF BRACKET J9414-68
ing.
(5) The TPS voltage must now be tested and (if
necessary) adjusted. Refer to the following: Throttle Fig. 35 Linkage Measurement—Diesel
Position Sensor Testing. wide open throttle (WOT), the output voltage must
be 2.2-to-2.9 volts higher than at idle speed. I f volt
THROTTLE POSITION SENSOR TESTING age is not correct, proceed to adjusting linkage.
(6) The linkage rod (Fig. 36) connecting the throt
CAUTION: Before attempting to test the TPS, verify
tle lever to the fuel injection pump lever is adjust
the linkage adjustment dimension (Fig. 35). This
able. To prevent damage to the ends of linkage,
dimension MUST be 126.5 mm (5.0 inches) BEFORE
attach locking-type pliers to the flat (Fig. 36) located
testing. For linkage adjustment procedures, refer to
on the linkage rod before loosening locknuts.
Throttle Linkage Adjustment—Diesel Engine. This
(7) Loosen the right-hand-threaded nut (Fig. 36).
can be found in the Accelerator Pedal and Throttle
(8) Loosen the left-hand-threaded nut (Fig. 36).
Cable section of this group.
(9) Slowly rotate the flat (Fig. 36) on the linkage
rod (lengthen or shorten) to achieve 1.0 volt (± .2
CAUTION: Before testing the TPS, verify that the volts) on the voltmeter with the linkage in the idle
engine is set at correct low idle speed. Refer to Idle position. At wide open throttle (WOT), the output
Speed Adjustment. voltage must be 2.2-to-2.9 volts higher than at idle
speed. DO NOT lengthen or shorten the linkage
(1) After confirming the correct linkage adjustment r o d more t h a n 1 m m from the dimension shown
and idle speed, proceed to the following: i n (Fig. 35). I f voltage requirements cannot be
(2) Attach a paper clip into the center terminal met by linkage adjustment (125.6 to 127.6 mm),
(Fig. 34) of the TPS electrical connector. Do not replace the TPS.
remove the connector from the TPS for this test. (10) Tighten both nuts after adjustment.
(3) Attach the positive lead of a voltmeter to this (11) With the engine OFF, operate the throttle
paper clip and the negative lead to a good ground. from accelerator pedal and check for throttle lever
(4) Turn the ignition switch to the ON position. Do action and binding. Be sure throttle lever stop is
not start engine. against the low idle speed screw after throttle is
(5) The voltage at the TPS center terminal should released.
be 1.0 volt (± .2 volt) with linkage at idle position. At

POWERTRAIN
THROTTLE LEVER-TO-
THROTTLE INJECTION PUMP LEVER CONTROL MODULE
LEVER LINKAGE ROD (POM)
BALL
Fig. 37 PCM Location and Mounting

(2) Carefully unplug the three 32-way connectors
from PCM.
(3) Remove three PCM mounting bolts and remove
THROTTLE
LEVER PCM from vehicle.
INSTALLATION
RIGHT-HAND-
THREADED
(1) Install PCM and mounting bolts to vehicle.
THROTTLE FLAT NUT (2) Tighten bolts to 4 N-m (35 in. lbs.).
POSITION LEFT-HAND-
THREADED
(3) Check pin connectors in the PCM and the three
SENSOR
NUT J9414-67 32-way connectors for corrosion or damage. Repair
as necessary.
Fig. 36 Throttle Lever Linkage Adjustment—Diesel (4) Install three 32-way connectors.
(12) Be sure of wide open throttle (WOT) when (5) Install battery cable.
accelerator pedal is pressed to the floor. This is
checked by observing throttle lever breakover posi AIR CLEANER HOUSING/AIR CLEANER ELEMENT
tion. Proceed to the following:
TESTIKG AIR CLEANER ELEMENT
(a) Key OFF and engine OFF for this test.
Do not attempt to unnecessarily remove the
(b) Two people are needed for this test. From
top of the air cleaner housing for air cleaner
inside of the vehicle, press the accelerator pedal
element inspection on diesel engines.
about half-way to the floor. Movement of both the
The air cleaner (filter) housing is equipped with an
throttle lever and throttle lever-to-injection pump
air Filter Minder® gauge (Fig. 38). This air flow
lever linkage rod (Fig. 36) should be observed.
restriction gauge will determine when the air cleaner
(c) Continue to press the accelerator pedal to the
element is restricted and should be replaced.
floor. I f throttle lever breakover is operating cor
The Filter Minder® consists of a diaphragm and
rectly, the throttle lever-to- injection pump lever
calibrated spring sealed inside of a plastic housing
linkage rod should have stopped moving while the
(Fig. 39). A yellow colored disc attached to the dia
throttle lever continues to move towards the rear
phragm moves along a graduated scale on the side of
of vehicle.
the Filter Minder. After the engine has been shut off,
(13) Again, check and verify low idle speed. Adjust
a ratcheting device located within the Filter Minder
if necessary.
will hold the yellow disc at the highest restriction
that the air cleaner element has experienced. A drop
POWERTRAIN CONTROL MODULE
in air pressure due to an air cleaner element restric
The PCM is located in the engine compartment
tion moves the diaphragm and the yellow disc will
(Fig. 37). indicate the size of the air drop.
REMOVAL
(1) Disconnect the negative battery cable at bat
tery.
If the Filter Minder gauge has reached the red col
ored zone, and after an examination of the air
cleaner (filter) element, the element appears to be
clean, the high reading may be due to a temporary
condition such as snow build-up at the air intake.
Temporary high restrictions may also occur i f the air
cleaner (filter) element has gotten wet such as during
a heavy rain or snow. I f this occurs, allow the ele
ment to dry out during normal engine operation.
Reset the rubber button on the top of the Filter
Minder and retest after the element has dried.
(1) Loosen the air inlet tube clamp at air cleaner
housing inlet (Fig. 38). Remove this. tube at air
cleaner housing cover.
Fig. 38-Filter Minder—Location—Diesel Engine (2) The housing cover is equipped with four (4)
spring clips (Fig. 38) and is hinged at the front with
CAUTION: Certain engine degreasers or cleaners plastic tabs. Unlatch the clips from the top of air
may discolor or damage the plastic housing of the cleaner housing and tilt the housing cover up and
Filter Winder. Cover and tape the Filter Minder if any forward for cover removal.
engine degreasers or cleaners are to be used. (3) Remove the air cleaner element from air
cleaner housing.
PRESS BUTTON
TO RESET
(4) Before installing a new air cleaner element,
clean inside of air cleaner housing.
(5) Position air cleaner cover to tabs on front of air
cleaner housing. Latch the four spring clips to seal
cover to housing.
(6) Install the air inlet tube at air cleaner housing
inlet. Note the hose alignment notches at both the
inlet hose and air cleaner cover (Fig. 38).
(7) Position the tube clamp to the inlet tube and
tighten to 3 N-m (25 in. lbs.) torque.
INTAKE MANIFOLD AIR TEMPERATURE SENSOR

The intake manifold air temperature sensor is
located on the top of intake manifold and to the rear
of the intake manifold heater (Fig. 40).
mEmowAL
TO AIR (1) Disconnect the electrical connector at the sen
FILTER HOUSING sor.
J9425-4 (2) Remove the sensor (Fig. 40) the from intake
manifold.
Fig, 39 Filter Minded—Diesel Engine
INSTALLATION
To test, turn the engine off. I f the yellow disc (Fig. (1) Install sensor to intake manifold. Tighten to 28
39) has reached the red colored zone on the gradu N-m (20 ft. lbs.) torque.
ated scale, . the air cleaner element should be (2) Install electrical connector.
replaced. Refer to the proceeding removal/installation
paragraphs. INTAKE MANIFOLD AIR HEATER ELEMENTS
Resetting the F i l t e r Minder: After the air The intake manifold air heater elements are
cleaner (filter) element has been replaced, press the located within the top cover of the intake manifold
rubber button on the top of the Filter Minder (Fig. (Fig. 41). I f replacement of the elements is necessary,
39). This will allow the yellow colored disc to reset. the intake manifold • cover must be removed. Refer to
After the button has been pressed, the yellow disc Intake Manifold Removal/Installation in Group 11.
should spring back to the UP position.

FRONT OF ENGINE AIR TEMPERATURE SENSOR BATTERY
SENSOR ELECTRICAL (LEFT SIDE)
CONNECTOR CABLES TO
BATTERY (+)
INTAKE AIR
HEATER RELAYS (2)
INTAKE
MANIFOLD p u E L
(UPPER HALF) WN SOLENOID RELAY

S H U T D O
SOLENOID ELECTRICAL TRIGGER

J9414-93 WIRES (4)
CONNECTOR
Fig. 40 Air Temperature Sensor Location—Diesel Fig. 42 Intake Manifold Air Heater Relays
INTAKE MANIFOLD AIR HEATER (2) Disconnect the four relay trigger wires at both
COVER ELEMENTS relays (Fig. 42). Note the position of wiring before
removing.
(3) Lift the four rubber shields from the four
cables (Fig. 42).
(4) Remove the four nuts at the cable connectors
(Fig. 42). Note the position of wiring before removing.
(5) Remove the three relay mounting bracket bolts
(Fig. 42) and remove relay assembly.
INSTALLATION
(1) Install the relay assembly to the inner fender.
Tighten mounting bolts to 4.5 N-m (40 in. lbs.)
torque.
(2) Connect the eight electrical connectors to the
relays.
GASKET (3) Connect battery cables to both batteries.

The vehicle speed sensor is located on the speed
ometer pinion gear adapter (Fig. 43). The pinion gear
adapter is located on the extension housing of the
Fig. 41 Intake Manifold Air Heater Elements
transmission (drivers side).
INTAKE MANIFOLD AIR HEATER RELAYS
The relays are located in the engine compartment, REMOVAL
bolted to the left inner fender below the left battery (1) Raise and support vehicle.
(Fig. 42). (2) Disconnect the electrical connector from the
sensor.
REMOVAL (3) Remove the sensor mounting bolt (Fig. 44).
The mounting bracket and both relays are replaced (4) Remove the sensor (pull straight out) from the
as an assembly. speedometer pinion gear adapter (Fig. 44). Do not
(1) Disconnect both negative battery cables at both remove the gear adapter from the transmission.
batteries.
verify speed sensor is fully seated (mounted
SENSOR
ELECTRICAL flush) to speedometer pinion gear adapter.
CONNECTOR (3) Tighten sensor mounting bolt to 2.2 N-m (20 in.
lbs.) torque.
(4) Connect electrical connector to sensor.
WATER-IN-FUEL SENSOR
The water-in-fuel sensor is located at the bottom of
the fuel filter/water separator. Refer to Fuel Filter/
Water Separator in this section of the group for
removal and installation procedures.
TRANSMISSION SPECIFICATIONS
EXTENSION
HOUSING
ENGINE DATA PLATE SPECIFICATIONS
on the Engine Data Plate, and the specifications used
in this manual, use specifications on data plate. The
Engine Data Plate is located on the engine timing
J9414-60 gear cover (Fig. 45).
Fig. 43 Vehicle Speed Sensor Location—Typical
SPEEDOMETER
PINION GEAR
ELECTRICAL
CONNECTOR
O-RING
\
SENSOR
MOUNTING
N
IG V-4
TIMING
GEAR
BOLT COVER
Fig. 45 Engine Data Plate Location

SPEEDOMETER PINION TOiOUE SPECIFICATIONS—DIESEL
GEAR ADAPTER
DESCEIPTION TORQUE
VEHICLE O-RING Engine Speed Sensor
SPEED
SENSOR
Nuts/Bolts .24 N-m (18 ft. lbs.)
J9314-188
Intake Manifold Air Temp.
Sensor 28 N-m (20 ft. lbs.)
Fig. 44 Sensor Removal/Installation
Intake Manifold Air Heater
INSTALLATION Relay Bolts .4.5 N-m (40 in. lbs.)
(1) Clean the inside of speedometer pinion gear PCM Mounting Bolts . .4 N-m (35 in. lbs.)
adapter before installing speed sensor. Vehicle Speed Sensor
(2) Install sensor into speedometer gear adapter Mounting Bolt .2.2 N-m (20 in. lbs.)
and install mounting bolt. Before tightening bolt,
BR STEERING 19 - 1
STEERING
CONTENTS
Page page
POWER STEERING GEAR 11 STEERING LINKAGE 19

POWER STEERING PUMP 3 STEERING LINKAGE—IFS SUSPENSION 20
POWER STEERING 1 STEERING LINKAGE—LINK/COIL SUSPENSION . 22
STEERING COLUMN 15
POWER S T E E R I N G
INDEX
page

POWER STEERING SYSTEM DIAGNOSIS
CHARTS
DIAGNOSIS A N D TESTING the end of it's travel. Hiss is a high frequency noise
similar to that of a water tap being closed slowly. The
POWER STEERING SYSTEM DIAGNOSIS CHARTS noise is present in all valves that have a high velocity
There is some noise in all power steering systems. fluid passing through an orifice. There is no relation
One of the most common is a hissing sound evident at ship between this noise and steering performance.
a standstill parking. Or when the steering wheel is at
STEERING NOISE

OBJECTIONAL HISS 1 . Damaged steering coupler to dash panel 1. Check and repair seal at dash panel.
OR WHISTLE seal.
2. Noisy valve in power steering gear. 2. Replace steering gear.
RATTLE OR CLUNK 1. Gear mounting bolts loose. 1. Tighten bolts to specification.
2. Loose or damaged suspension components. 2. Inspect and repair suspension.
3. Loose or damaged steering linkage. 3. Inspect and repair steering linkage.
4. Internal gear noise. 4. Replace gear.
5. Pressure hose in contact with other 5. Reposition hose.
components.
CHIRP OR SQUEAL 1. Loose belt. 1. Adjust or replace.
WHINE OR GROWL 1. Low fluid level. 1. Fill to proper level.
2. Pressure hose in contact with other 2. Reposition hose.
components.
3. Internal pump noise. 3. Replace pump.
SUCKING AIR SOUND 1. Loose return line clamp. 1. Replace clamp.
2. O-ring missing or damaged on hose fitting. 2. Replace o-ring.
3. Low fluid level. 3. Fill to proper level.
4. Air leak between pump and reservoir. 4. Repair as necessary.
SCRUBBING OR 1. Wrong tire size. 1. Verify tire size.
KNOCKING
2. Wrong gear. 2. Verify gear.
BINDING AND STICKING
DIFFICULT TO TURN WHEEL 1. Low fluid level. 2 . Fill to proper level.

STICKS OR BINDS
2. Tire pressure. 2. Adjust tire pressure.
3 . Steering components. 3. Inspect and lube.
4 . Loose belt. 4. Adjust or replace.
5 . Pump flow control valve. 5. Test and replace if necessary.
6. Column coupler binding. 6. Replace coupler.
7 . Steering gear worn or out of 7. Repair or replace gear.
adjustment.
INSUFFICIENT ASST. OR POOR RETURN TO CENTER
HARD TURNING OR MOMENTARY 1. Tire pressure. 1 . Adjust tire pressure.

INCREASE IN TURNING EFFORT
2 . Low fluid level. 2 . Fill to proper level.
3. Loose belt. 3. Adjust or replace.
4 . Lack of lubrication. 4. Inspect and lubricate steering and
suspension compnents.
5. Low pump pressure. 5 . Test and repair as necessary.
6 . Internal gear leak. 6 . Test and repair as necessary.
STEERING WHEEL DOES NOT 1. Tire pressure. 1. Adjust tire pressure.

WANT TO RETURN TO CENTER
POSITION
2 . Wheel alignment. 2. Align front end.
3 . Lack of lubrication. 3 . Inspect and lubricate steering and
suspension compnents.
4. High friction in steering gear. 4 . Test and repair as necessary.
LOOSE STEERING AMD VEHICLE LEAD
CONDITION POSSIBLE CAUSE f:ORRECTIOW
EXCESSIVE PLAY IN STEERING 1 . Worn or loose suspension or 1. Inspect and repair as necessary.
WHEEL steering components.
2 . Worn or loose wheel bearings. 2 . Inspect and repair or adjust
bearings.
3 . Steering gear mounting. 3 . Tighten gear to specification.
4 . Gear out of adjustment. 4 . Adjust gear to specification.
5 . Worn or loose steering coupler. 5 . Inspect and replace as
necessary.
VEHICLE PULLS OR LEADS TO 1. Radial tire lead. 1. Rotate tires.

ONE SIDE.
2. Brakes dragging. 2 . Repair as necessary.
3 . Wheel alignment. 3 . Align front end.
BR STEERING 19 - 3
POWER STEERING PUMP
INDEX
page page
DESCRIPTION AND OPERATION POWER STEERING PUMP—DIESEL ENGINE . . . 6

POWER STEERING PUMP 3 POWER STEERING PUMP—GASOLINE
DIAGNOSIS AND TESTING ENGINE 4
POWER STEERING PUMP FLOW RATE AND PUMP PULLEY 8
PRESSURE TEST 3 SPECIFICATIONS
PUMP LEAKAGE DIAGNOSIS . . . . . . . . . . . . . . . 4 TORQUE CHART . . . . . . . . . . . . . . . ...... 9
POWER STEERING PUMP—INITIAL POWER STEERING PUMP 10
OPERATION 4
P-SERIES PUMP RESERVOIR . . . . . . . . . . . . . . . . 8
DESCRIPTION A N D OPERATION DIAGNOSIS AND TESTING
POWER STEERINI P U i P POWER STEERING PUMP FLOW RATE AND

The Saginaw P-Series pump is used on these vehi PRESSURE TEST
cles (Fig. 1). The following procedure is used to test the opera
Hydraulic pressure is provided for the power steer tion of the power steering system on the vehicle. This
ing gear by the belt driven power steering pump. The test will provide the flow rate of the power steering
power steering pump is a constant flow rate and dis pump along with the maximum relief pressure. Per
placement, vane-type pump. form test any time a power steering system problem
The pump is connected to the steering gear via the is present. This test will determine i f the power
pressure hose and the return hose. The pump shaft steering pump or power steering gear is not function
has a pressed-on pulley that is belt driven by the ing properly. The following pressure and flow test is
crankshaft pulley. performed using Pressure/Flow tester, Special Tool
Trailer tow option vehicles are equipped with a 6815 (Fig. 2).
power steering pump oil cooler. The oil cooler is
mounted to the radiator support.
NOTE; Power steering pumps are not interchange
able with pumps installed on other vehicles.
9519-1
Fig. 2 Pressure Test Gauge

POWER STEERING PUMP FLOW AND
PRESSURE TEST PROCEDURE
(1) Check belt tension and adjust as necessary.
(2) Disconnect high pressure hose at gear or pump.
Use a container for dripping fluid.
Fig. 1 Saginaw Pump—P-Series
19 - 4 STEERING BR

(3) Connect pressure gauge from Power Steering PUMP LEAKAGE DIAGNOSIS
Analyzer Tool k i t 6815 to both hoses using appropri
ate adapter. Connect spare pressure hose to gear or
pump. SERVICE PROCEDURES
(4) Open the test valve completely.
(5) Start engine and let idle long enough to circu POWER STEERING PUMP—INITIAL OPERATION
late power steering fluid through flow/pressure test
gauge and to get air out of the fluid. Then shut off CAUTION: The fluid level should be checked with
engine. engine off to prevent injury from moving compo
(6) Check fluid level, add fluid as necessary. Start nents. Use MOPAR Power Steering Fluid or equiva
engine again and let idle. lent. Do not use automatic transmission fluid and
(7) Gauge should read below 1034 kPa (150 psi), i f do not overfill.
above, inspect the hoses for restrictions and repair as
Wipe filler cap clean, then check the fluid level.
necessary. The initial pressure reading should be in
The dipstick should indicate C O L D when the fluid is
the range of 345-552 kPa (50-80 psi). The flow meter
at normal temperature.
should read between 1.3 and 1.9 GPM.
(1) Fill the pump fluid reservoir to the proper level
CAUTION; The following test procedure involves and let the fluid settle for at least two (2) minutes.
testing maximum pump pressure output and flow (2) Start the engine and let run for a few seconds
control valve operation. Do not leave valve closed then turn engine off.
for more than five seconds as the pump could be (3) Add fluid i f necessary. Repeat the above proce
damaged. dure until the fluid level remains constant after run
ning the engine.
(8) Close valve fully three times and record high (4) Raise the front wheels off the ground.
est pressure indicated each time. A l l three read (5) Slowly turn the steering wheel right and left,
ings must he above specifications and w i t h i n lightly contacting the wheel stops at least 20 times.
345 k P a (50 psi) of each other. (6) Check the fluid level add i f necessary.
• Pressures above specifications but not within (7) Lower the vehicle, start the engine and turn
345 kPa (50 psi) of each other, replace pump. the steering wheel slowly from lock to lock.
• Pressures within 345 kPa (50 psi) of each other (8) Stop the engine and check the fluid level and
but below specifications, replace pump. refill as required.
(9) I f the fluid is extremely foamy, allow the vehi
NOTE: Refer to pump relief pressure chart, cle to stand a few minutes and repeat the procedure.
CAUTION: Do not force the pump to operate REMOVAL AND INSTALLATION

against the stops for more than 2 to 4 seconds at a
time because, pump damage will result. POWER STEERING PUMP—GASOLINE ENGINE
(9) Open the test valve, turn steering wheel WARNING: DO NOT REMOVE THE WATER PUMP
extreme left and right positions against the stops. COOLANT TUBE UNLESS THE COOLANT SYSTEM
Record the highest indicated pressure at each posi HAS BEEN DEPRESSURIZED AND DRAINED.
tion. Compare readings to specifications chart. I f
highest output pressures are not the same against
either stop, the gear is leaking internally and must REMOVAL
be repaired. (1) Remove the serpentine drive belt, refer to
Group 7 Cooling.
PUMP SPECIFICATION CHART (2) Remove the hoses from the power steering
pump and cap the fittings.
RELIEF PRESSURE FLOW (3) Remove battery ground cable and unthread
ENGINE
(P.S.I.) (G.P.M.) stud from cylinder head, do not remove from bracket.
3.9L 1400 to 1500 2.4 to 2.8 (4) Loosen upper bracket bolt and remove the
lower bracket to engine block bolts.
5.2L 1400 to 1500 2.4 to 2.8
(5) Pivot the pump assembly past the coolant tube.
5.9L 1400 to 1500 2.7 to 3.1 (6) Remove the upper stud and remove upper bolt
8.0L 1450 to 1550 3.1 to 3.5 from cylinder head.
(7) Remove steering pump and mounting bracket
5.9L Diesel 1400 to 1500 2.7 to 3.1
from engine as an assembly.
STEERING 19 - 5
PUMP LEAKAGE
J9419-33
19-6 STEERING BR
(8) Remove the pump pulley, to access pump (3) Install steering pump assembly on the engine
attaching bolts. block. Install the upper stud and bolt in bracket.
(9) Remove the front pump bracket (Fig. 3). On (4) Pivot the pump down past the coolant tube and
8.0L engine remove rear pump bracket (Fig. 4). install the lower bolts in bracket.
(5) Tighten the bolts and nut to 41 N-m (30 ft.
lbs.).
(6) Connect the hoses to the pump.
(7) Install the serpentine drive belt refer to Group
7, Cooling for belt routing.
(8) Fill the reservoir with power steering fluid,
refer to Pump Initial Operation
POWER STEERING PUIVSP—DIESEL ENGINE
REMOVAL
(1) Remove and cap steering pump hoses and vac
uum pump vacuum line.
(2) Remove the sender unit from engine block and
plug hole in block (Fig. 5).
Fig. 3 Pump Mounting 3.9L, 5.2L and 5.9L
FRONT BRACKET
PUMP ENGINE BLOCK
Fig. 5 Oil Pressure Sending Unit

(3) Remove and cap the oil feed line from the bot
tom of the vacuum pump (Fig. 6).
(4) Remove the lower bolt that attaches the vacu
um/steering pump assembly to the engine block.
Remove the nut from the steering pump attaching
bracket (Fig. 6).
PULLEY J9419-27 (5) Remove upper bolt from the pump assembly
(Fig. 7) and remove the assembly.
Fig. 4 Pump Mounting 8.0L (6) Remove the mounting gasket.
INSTALLATION (7) Remove the steering pump to vacuum pump
( 1 ) Install the front pump bracket and tighten bracket attaching nuts (Fig. 8).
bolts to 47 N-m (35 ft. lbs.). On 8.0L engine install (8) Slide the steering pump from the bracket. Use
rear pump bracket and tighten nut to 47 N-m (35 ft. care not to damage the internal oil seal in the vac
lbs.), tighten bolts to 24 N-m ( 1 8 ft. lbs.). uum pump (Fig. 9).
(2) Install the pump pulley. (9) Remove the two pump body spacers.
BR SIEEFtlNG 19-7
REMOVAL A N D I N S T A L L A T I O N fContinued)
Fig. 8 Oii Feed Line Fig. 8 Bracket Mounting Nuts

PUMP SHAFT VACUUM
PUMP BRACKET
SPACERS J9119-69
Fig. 7 Pump Assembly Upper Bolt Fig. 9 Steering Pump & Vacuum Pump
INSTALLATION (3) Install the vacuum pump bracket to steering

(1) Install the two pump body spacers. pump nuts and tighten to 24 N-m (18 ft. lbs.).
(2) Rotate the drive gear until the steering pump (4) Position new gasket on vacuum pump assem
and vacuum pump drive dogs align. Install the steer bly. Use sealer i f necessary to retain the gasket.
ing pump onto the vacuum pump bracket. Use care (5) Align and install the pump assembly on the
to avoid damaging the oil seal i n the vacuum pump engine. Ensure the steering pump stud is inserted
during installation. The steering pump housing into the block bracket. Tighten the pump- to-engine
and spacers must mate completely w i t h 'the block attaching bolts to 77 N-m (57 ft. lbs.).
vacuum pump bracket. (6) Install the steering pump to attaching bracket
nut and tighten to 24 N-m (18 ft. lbs.).
19 - 8 STEERING BR
(7) Remove plug and install the oil pressure send
ing unit and electrical connector.
(8) Install the oil feed line to the vacuum pump.
Tighten the oil line connection to 7 N-m ( 6 0 in. lbs./ 5
ft. lbs.).
(9) Install the fluid hoses to the power steering
pump. Tighten the pressure fitting at the pump to 3 1
N-m ( 2 3 ft. lbs.).
( 1 0 ) Install and clamp the hose on the vacuum
pump.
( 1 1 ) Fill the reservoir with power steering fluid,
refer to Pump Initial Operation.
( 1 2 ) Start the engine and check the operation of
the brakes.
P U I P PULLEY
Fig. 11 Pulley Installation
REMOVAL
(1) Remove pump assembly. pulley outward approximately 0.5 mm ( 0 . 0 2 0 in.). I f
( 2 ) Remove pulley from pump with Puller C-4333
noise increases, press on 1.0 mm (0.040 in.). Be care
ful that pulley does not contact mounting bolts.
(Fig. 1 0 ) .
P^SERIES PUIP RESERW01R
REMOVAL
NOTE: Discard all O-ring seals during disassembly,

they are not re-usable.
( 1 ) Remove pump assembly.

( 2 ) Remove mounting studs and pressure fitting.
Rock reservoir by hand or use a soft face mallet and
remove reservoir (Fig. 1 2 ) .
( 3 ) Remove O-ring seals from housing and discard.
( 4 ) Remove flow control valve and spring from
housing (Fig. 13).
INSTALLATION
Fig. 10 Pulley Removal NOTE: Clean all parts before installation. Lubricate
INSTALLATION new O-ring seals with MOPAR Power Steering Fluid
(1) Replace pulley i f bent, cracked, or loose. or an equivalent product.
( 2 ) Install pulley on pump with Installer C - 4 0 6 3 - B
(Fig. 11) flush with the end of the shaft. Ensure the ( 1 ) Install flow control valve and spring.
tool and pulley remain aligned with the pump shaft. ( 2 ) Install new O-ring seals on housing and install
(3) Install pump assembly. reservoir.
(4) With Serpentine Belts; Run engine until warm ( 3 ) Install mounting studs and tighten to 4 8 N-m
(5 min.) and note any belt chirp. I f chirp exists, move (35 ft. lbs.). •
( 4 ) Install fitting in flow control valve bore tighten
to 7 5 N-m ( 5 5 ft. lbs.).
BR STEERING 11 - 9
tEMOVAL AND INSTALLATION (Continued)
EXPANSION PLUG - DO NOT REMOVE; RESERVOIR
IF DEFORMED OR DISLODGED,
REPLACE HOUSING
CAP
HOUSING STUDS
48 N-m
FITTING
75 N-m
SEALS SEAL 9119-9
Fig. 12 Pump Reservoir

VALVE AND
SPRING
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Reservoir Bolts 56 N-m (42 ft. lbs.)
Flow Control Valve . 75 N-m (55 ft lbs.)
Pressure Line 3 1 N-m(23 ft lbs.)
Oil Cooler Bolt. .20 N-m (15 ft lbs.)
Pump Mounting—3.9L, 5.2L & 5.9L
Bracket to Pump 47 N-m (35 ft. lbs.)
Bracket to Engine . . . . . . . . . . .41 N-m(30 ft. lbs.)
Pump Mounting—8.0L
Rear Bracket to Pump .47 N-m (35 ft. lbs.)
Rear Bracket to Front Bracket .24 N-m (18 ft. lbs.)
Bracket to Engine .41 N-m (30 ft. lbs.)
Pump Mounting—Diesel
J8919-101 Pump to Vacuum Pump. 24 N-m (18 ft. lbs.)
Pump Assembly to Engine 77 N-m (57 ft. lbs.)
Fig. 13 Flow Control Waive Pump to Support Bracket 24 N-m (18 ft. lbs.)
19 -10 STEERING
SPECIAL TOOLS
POWER STEERING PUMP
Analyzer Set, Power Steering Plow/Pressure 6815 Puller C-4333
Adapters, Power Steering Flow/Pressure Tester Installer, Power Steering Pulley C-4063-B
6893
BR STEERING 19 -11
POWER STEERING GEAR
INDEX
page page
GENERAL INFORMATION ADJUSTMENTS

FRAME COATINGS INFORMATION . 11 STEERING GEAR 12
DESCRIPTION AND OPERATION SPECIFICATIONS
POWER STEERING GEAR 11 POWER STEERING GEAR SPECIFICATION . . . 14
DIAGNOSIS AND TESTING TORQUE CHART 14
POWER STEERING GEAR LEAKAGE SPECIAL TOOLS
DIAGNOSIS 11 POWER STEERING GEAR 14
POWER STEERING GEAR 11
GENERAL INFORMATION worm shaft turns the pitman shaft, which turns the
steering linkage.
FRAME COATINGS INFORMATION The steering gear can be adjusted,but i t is serviced
as an assembly, no internal parts are serviced.
frames: DIAGNOSES AND TESTING
VEHICLE BUILD 11th POSITION FRAME POWER STEERING GEAR LEAKAGE DIAGNOSIS
LOCATION VIN CHARACTER COATING
St. Louis North J E-Coat REMOVAL AND INSTALLATION
Dodge City S Wax Coat POWER STEERING GEAR
Saltillo Mexico G Wax Coat REMOVAL

Lago Alberto (1) Place the front wheels in a straight-ahead posi
M Wax Coat tion.
Mexico
(2) Disconnect and cap the fluid hoses from steer
Replacement fasteners and torque values for ing gear.
frame attached components may vary depending on (3) Remove coupler pinch bolt at the steering gear
frame coatings. Ensure the replacement fastener is and slide shaft off gear (Fig. 1).
designed for the specific frame coating. Refer to the (4) Mark the pitman shaft and pitman arm for
Torque Specifications Chart at the end of each installation reference. Remove the pitman arm from
group to determine the correct torque value. the shaft with Puller C-4150A (Fig. 2).
(5) Remove steering gear retaining bolts and nuts.
Remove the steering gear from the vehicle.
DESCRIPTION AND OPERATION INSTALLATION

(1) Position the steering gear on the frame rail and
POWER STEERING GEAR install the bolts. Tighten mounting bolts to specifica
The power steering gear is a recirculating ball type tions.
gear. The gear acts as a rolling thread between the (2) Align steering coupler on gear shaft. Install
worm shaft and rack piston. The worm shaft is sup pinch bolt and tighten to 49 N-m (36 ft. lbs.) torque.
ported by a thrust bearing at the lower end and a (3) Align and install the pitman arm.
bearing assembly at the upper end. When the worm (4) Install the washer and retaining nut on the pit
shaft is turned the rack piston moves. The rack pis man shaft. Tighten the nut to 251 N-m (185 ft. lbs.).
ton teeth mesh with the pitman shaft. Turning the (5) Connect fluid hoses to steering gear, tighten to
31 N-m (23 ft. lbs.). Add fluid, refer to Power Steer
ing Pump Initial Operation.
19 - 1 2 STEERING BR
1. SIDE COVER LEAK - TORQUE SIDE 3. PRESSURE LINE FITTING - TOR

COVER BOLTS TO 60 N-m (45 FT. QUE THE HOSE FITTING NUT TO
LBS.). REPLACE THE SIDE COVER 27 N-m (20 FT. LBS.). IF LEAKAGE
SEAL IF THE LEAKAGE PERSISTS. PERSISTS, REPLACE THE SEAL
2. ADJUSTER PLUG SEAL - REPLACE 4. PITMAN SHAFT SEALS - REPLACE

THE ADJUSTER PLUG SEALS. THE SEALS.
5. TOP COVER SEAL - REPLACE THE

SEAL J9219-29
STEERING
J9419-20
Fig. 1 Coiumn Shaft
ADJUSTHEIfYS
STEERING GEAR
CAUTION: Steering gear m u s t be adjusted in the Fig. 2 Pitman Arm

proper order. If a d j u s t m e n t s are not performed in
and drain the fluid. Then mount gear in a vise to
o r d e r , gear damage a n d improper steering response
perform adjustments.
may result.
W O R M THRUST BEARING PRELOAD

NOTE: Adjusting the s t e e r i n g gear in the vehicle is
(1) Remove adjuster plug locknut (Fig. 3).
n o t recommended. R e m o v e gear from the vehicle
BR - STEERING 19 - 1 3
Fig. 5 Remarking The Housing
Fig. 3 Loosening the Adjuster Piug FIRST

MARK
(2) Turn the adjuster i n with Spanner Wrench
0-4381. Tighten the plug and thrust bearing in the
housing until firmly bottomed i n housing.
(3) Place an index mark on the housing even with
one of the holes i n adjuster plug (Fig. 4).
J9219-30
Fig, 6 Aligning To The Second Mark

(6) Install and tighten locknut to 108 N-m (80 ft.
lbs.). Be sure adjustment cap does not turn while
tightening the locknut.
J8919-58
OVER-CENTER
Fig. 4 Alignment Marking On Housing (1) Rotate the stub shaft from stop to stop and
(4) Measure back (counterclockwise) 13 mm (0.50 count the number of turns.
in) and mark housing (Fig. 5). (2) Starting at either stop turn the stub shaft back
(5) Rotate adjustment cap back (counterclockwise) 1/2 the total number of turns. This is the center of
with spanner wrench until hole is aligned with the the gear travel (Fig. 7).
second mark (Fig. 6).
19 - 14 STEERING — — — BR
(5) Turn the adjuster in until torque to turn stub
shaft is 0.6 to 1.2 N-m (6.0 to 10.0 in. lbs.) more than
previous reading recorded.
(6) Prevent the adjuster screw from turning while
tightening adjuster lock nut. Tighten the adjuster
lock nut to 27 N-m (20 ft. lbs.).
SPECIFICATIONS
POWER STEERING GEAR SPECIFICATION
Steering Gear
Type Recirculating Ball
Gear Code & Ratio
BN 17.5:1
HF. . . . . .16-13:1
Wormshaft Bearing
Preload 0.45-1.13 N-m (10-15 in. lbs.)
Pitman Shaft Overcenter Drag
New Gear (under 400 miles) 0.45-0.90 N-m
(6-10 in. lbs.) + Wormshaft Preload
Fig. 7 Steering Gear Centered Used Gear (over 400 miles) .0.5-0.6 N-m
(3) Turn the pitman shaft adjuster screw back (4-5 in. lbs.) + Wormshaft Preload
(COUNTERCLOCKWISE) until extended, then turn
TORQUE CHART
back in (CLOCKWISE) one full turn.
(4) Place the torque wrench in the vertical position
DESCRIPTION TORQUE
on the stub shaft. Rotate the wrench 45 degrees each
Steering Gear Mounting
side of the center and record the highest rotational
E-Coat Frame Bolts 190 N-m (140 ft. lbs.)
torque on center (Fig. 8).
Wax Coat Frame Bolts 244 N-m (180 ft. lbs.)
Line Fittings
Pressure 31 N-m (23 ft. lbs.)
Return 31 N-m (23 ft. lbs.)
Steering Gear
Adjustment Cap Locknut. . . 108 N-m (80 ft. lbs.)
Adjustment Screw Locknut. . . .58 N-m (43 ft. lbs.)
Pitman Shaft Nut 251 N-m (185 ft. lbs.)
Rack Piston Plug 149 N-m (110 ft. lbs.)
Side Cover Bolts . . .61 N-m (45 ft. lbs.)
Return Guide Clamp Bolt. . 5 N-m (4 ft. lbs.)
SPECIAL TOOLS
POWER STEERING GEAR
Fig 8 Checking Over-center Rotation Torque
Remover, Pitman Arm C-4150A

BR STEERING 19 - 1 5
STEERING COLUMN
INDEX
page page
G E N E R A L INFORMATION STEERING COLUMN 16
STEERING COLUMN 15 SPECIFICATIONS
DIAGNOSIS AND TESTING TORQUE CHART 18
IGNITION SWITCH 16
GEAR SHIFT LEVER 18
G E N E R A L INFORMATION THE AIRBAG S Y S T E M COMPONENTS YOU MUST

FIRST DISCONNECT AND ISOLATE THE BATTERY
STEERING COLUMN NEGATIVE (GROUND) C A B L E . FAILURE TO DO S O
The Acustar tilt and standard column (Fig. 1) has COULD RESULT IN ACCIDENTAL DEPLOYMENT OF
been designed to be serviced as an assembly; less THE AIRBAG AND P O S S I B L E PERSONAL INJURY.
wiring, switches, shrouds, steering wheel, etc. Most THE FASTENERS, S C R E W S , AND BOLTS, ORIGI
steering column components can be serviced without NALLY USED FOR THE AIRBAG COMPONENTS,
removing the steering column from the vehicle. HAVE SPECIAL COATINGS AND A R E SPECIFI
CALLY DESIGNED FOR THE AIRBAG SYSTEM.
UPPER
THEY MUST NEVER B E R E P L A C E D WITH ANY SUB
SHROUD
STITUTES. ANYTIME A NEW FASTENER IS
NEEDED, R E P L A C E WITH THE C O R R E C T FASTEN
E R S PROVIDED IN THE S E R V I C E PACKAGE OR
FASTENERS LISTED IN THE PARTS BOOKS.
CAUTION: Do not hammer on steering column

shaft or shift tube.
CAUTION: Do not attempt to remove the pivot pins

to disassemble the tilting mechanism. Do not
remove ignition locking link, shaft lock plate or
plate retainer. This will damage the column (Fig. 2 )
and (Fig. 3 ) .
LOWER
SHROUD J9419-17
Fig. 1 Acustar Steering Column

SERVICE PRECAUTIONS
Safety goggles should be worn at all times when
working on steering columns.
To service the steering wheel, switches or the air-
bag, refer to the appropriate section of Group 8. Fol
low all WARNINGS.
WARNING: THE AIRBAG S Y S T E M IS A SENSITIVE,

COMPLEX ELECTRO-MECHANICAL UNIT. B E F O R E
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL Fig. 2 Observe Cautions
19-16 STEERING BR
(4) I f no binding is found, lightly file the ramp on

the ignition switch, (The ramp fits into the casting)
until binding no longer occurs.
STEERING COLUMN
WARNING: REMOVE AND ISOLATE THE NEGATIVE

(-) BATTERY C A B L E (GROUND) FROM THE BAT
TERY, THIS IS THE ONLY S U R E WAY TO DISABLE
THE AIRBAG SYSTEM. FAILURE TO DO THIS
MENT AND P O S S I B L E PERSONAL INJURY.
Fig. 3 Observe Cautions WARNING: WHEN A STEERING COLUMN HAS AN

DIAGNOSIS AND TESTING AIRBAG MODULE ATTACHED, NEVER P L A C E THE
COLUMN ON THE FLOOR OR OTHER S U R F A C E
IGNITION SWITCH WITH THE STEERING WHEEL OR MODULE FACE
DOWN.
T E S T AND REPAIR
I f the ignition switch effort is excessive, remove the CAUTION: Bumping, jolting and hammering on
ignition switch from the steering column. Refer to
steering column shaft and gear shift tube must be
Group 8D Ignition System. Using a key cylinder,
avoided during service procedures.
check the turning effort of the switch. I f the ignition
switch binds look for the following conditions.
(1) Look for rough areas or flash in the casting REMOVAL
and i f found remove with a file (Fig. 4). (1) Turn front wheels straight ahead and center
steering wheel.
CAUTION: DO NOT (2) Disconnect the negative (ground) cable from
REMOVE IGNITION FILE THIS AREA TO REMOVE
FLASHING AND PROVIDE the battery.
LOCKING LINK (3) Remove steering wheel and clock spring from
CLEARANCE TO ELIMINATE
BINDING column, refer to Group 8.
(4) Disconnect link rod in engine compartment i f
equipped with column shift. Pry rod out from grom
met i n the shift lever.
(5) Scribe or paint reference mark on the column
shaft-to-coupler. This will aid in column shaft instal
lation alignment. Remove the steering column shaft-
CAUTION: NEVER
REMOVE SHAFT to-coupler bolt (Fig. 5).
LOCK PLATE (6) Remove the dash panel cover under column.
(7) For column shift vehicles, make sure shift lever
is i n P a r k position. Pull cable and twist to remove
803f589b
from position arm. Push tab on bottom of cable
Fig. 4 Steering Coiumn Flash Removal And retainer, then squeeze sides to remove retainer from
Non-Serviceable Components column (Fig. 6).
(8) Remove tilt lever (if equipped) from column.
(2) Remove the link and slider and check the link (9) Remove the upper and lower lock housing
to see i f i t is bent. I f so replace with a new part. shroud and remove the lower fixed shroud.
(3) Put the slider in its slot in the sleeve and ver (10) Remove the turn signal multi-function switch
ify a loose fit over the length of the slot. I f the slider with a 7mm socket (Fig. 7).
binds in the slot at any point lightly file the slider (11) Loosen the upper Support Bracket nuts to
until clearance is achieved. allow some slack. This will aid in removal of the
upper fixed shroud.
BR • STEERING 19 - 1 7
STEERING KEY-IN SWITCH & MULTI-FUNCTION
COLUMN
SHIFT
LEVER J9419-21 SWITCH CONTROL J918J-2
Fig. 5 Steering Coupler Fig. 8 Steering Column Wiring

(13) Remove the wiring harness from the column
by prying out the plastic retainer buttons.
(14) Remove lower dash panel and toe plate fas
teners.
(15) Remove column from vehicle. Use care to
avoid damaging the paint or trim.
INSTALLATION
(1) Column shift vehicles, install a new grommet.
Use MOPAR® Multipurpose Lubricant, or equivalent,
to aid installation of the grommet. A new grommet
should be used when ever the rod is discon
nected from the lever.
(2) Remove the shipping lock pin i f necessary.
J948E-4 (3) Install the ground clip on the left spacer slot.
(4) Install column through floor pan.
Fig. 6 PRNDL Drive Cable (5) Position the column bracket shear pins on the
attaching studs. Install, but loose assemble the two
upper bracket nuts.
(6) With the front wheels in the straight-ahead
position. Align steering column shaft to the coupler.
Install pinch bolt and tighten to 49 N-m (36 ft. lbs.).
(7) Clip the wiring harness on the steering column.
Connect the multi-function switch wiring and tighten
with 7mm socket.
(8) Install the upper fixed shroud.
(9) Be sure both breakaway capsules are fully
seated in the slots in the column support bracket.
Tighten upper bracket nuts to 12 N-m (105 in. lbs.).
(10) Tighten the toe plate to floor pan attaching
nuts to 22.5 N-m (200 in. lbs.).
(11) Install the wiring connections to the column.
Install the lower fixed shroud.
(12) Column shift vehicles, install the PRNDL
Fig. 7 Multi-function Switch
driver cable. Place shifter in Park position. I f indica
(12) Remove electrical connections from Key-in tor needs adjusting turn recessed hex head screw
light, Ignition Switch, Horn and Clock Spring (Speed underneath cable retainer (Fig. 9).
Control) (Fig. 8). (13) Install the lock housing shrouds. Install the
tilt lever (if equipped).
19 - 1 8 STEERING BR
REMOVAL AND, INSTALLATION (Continued)
J948E-66
Fig. 9 PRNDL Adjuster

(14) Install the lower dash panel column cover.
(15) Install steering wheel on column, refer to 9419-43
Steering Wheel- Installation.
(16) Column shift vehicles, connect the shift link Fig. 10 Gear Shift Lever
rod to the transmission shift lever. Use MOPAR®
Multipurpose Lubricant, or an equivalent product, to (3) Carefully install the roll pin into the steering
aid the installation. column assembly and through the shift lever. I f the
(17) Check operation of the transmission shift roll pin binds check the alignment on the holes. Be
linkage and adjust as necessary. Refer to Group 21, sure roll pin is fully installed into the steering col
Transmission for the shift linkage adjustment. umn assembly.
(18) Connect the battery ground (negative) cable.
SPECIFICATIONS
GEAR SHIFT LEWER
TORQUE CHART
REMOVAL
(1) Support the steering column. assembly as DESCEIPTION TORQUE
shown in (Fig. 10) using a suitable size socket. Steering Wheel
(2) Using a drift of the appropriate size drive the Nut . . . . . . . . . . . . . . . . . .61 N-m (45 ft. lbs.)
roll pin out of the steering column and gear shift Steering Coupler
lever. Remove the gear shift lever from the steering
Bolt .49 N-m (36 ft. lbs.)
column assembly.
Steering Column
INSTALLATION Upper Bracket . . . . . . . . . . . .12 N-m (105 in. lbs.)
(1) Support the steering column using a suitable Toe Plate. . . . . . 23 N-m (200 in. lbs.)
size socket.
(2) Install the gear shift lever into the steering col
umn assembly. Align the roll pin holes in the gear
shift lever and the steering column assembly.
STEERING LINKAGE
INDEX
page
SERVICE PROCEDURES
STEERING LINKAGE 19
SERVICE PROCEDURES is damaged, i t should be replaced. Before installing a

new seal, inspect ball stud. Replace ball stud i f worn
STEERING LINKAGE and lubricate the ball studs with MOPAR Multi-Mile
Before removing any steering component, the boot age Lubricant, or an equivalent.
seals should be closely inspected for damage. I f a seal
19 - 20 STEERING BR
S T E E R I N G LINKAGE—IFS S U S P E N S I O N
INDEX
page page
GENERAL INFORMATION SPECIFICATIONS

FRAME COATINGS INFORMATION 20 TORQUE SPECIFICATIONS . . . . . . . 21
IFS—STEERING LINKAGE 20 SPECIAL TOOLS
REMOVAL AND INSTALLATION STEERING LINKAGE . . . . . . . 21
STEERING LINKAGE 20
GENERAL INFORMATION

frames:
VEHICLE BUILD 11th POSITION

LOCATION VIN CHARACTER COATII :

LINK
Saltiilo Mexico G Wax Coat J9419-37
Lago Alberto
M Wax Coat Fig. 1 IFS—Steering Linkage
Mexico

frame attached components may wary depending on
IPS—-STEERING LINKAGE
Standard and heavy duty steering linkage is used
with IFS suspensions (Fig. 1). Heavy duty linkage is
used on 8,800 and 10,500 GVW vehicles. Vehicles
with 10,500 GVW rating have a steering damper
mounted from a frame bracket to the centerlink.
Fig. 2 Tie Rod End

R E M O V A L AMD I N S T A L L A T I O N
REMOVAL
STEERING LINKAGE (1) Remove the cotter pin and nut from the tie-rod.
(2) Remove the tie-rod end ball studs from steering
NOTE: When servicing the steering linkage, use knuckles.
care to avoid damaging ball stud seals. Use puller (3) Remove inner tie-rod ends from center link.
C-38S4-A t o remove tie rod ends (Fig. 2). (4) I f equipped remove steering damper from cen
ter link and frame bracket.
BR STEERING 19 - 21
REHOWAL AND I N S T A L L A T I O N fContinued)
(5) Remove idler arm ball stud from center link. (9) After adjustment, tighten the tie-rod adjust
Remove idler arm stud plate from frame side rail. ment sleeve clamp bolt to 54 N-m (40 ft. lbs.).
(6) Remove pitman arm ball stud from center link.
(7) Mark the pitman arm and shaft positions for
installation reference. Remove pitman arm with SPECIFICATIONS
Puller C-4150A (Fig. 3).
DESCRIPTION TORQUE
Pitman Arm
Ball Stud Nut 88 N-m (65 ft. lbs.)
Shaft Nut. . . . . . . . . . . . . . . .251 N-m (185 ft. lbs.)
Idler Arm with Wax Coat Frame
Mounting Nuts LD 68 N-m (50 ft. lbs.)
Mounting Bolts HD .271 N-m (200 ft. lbs.)
Idler Arm with E-Coat Frame
Ball Stud Nut . . . .88 N-m (65 ft. lbs.)
Mounting Nuts LD 94 N-m (70 ft. lbs.)
Mounting Bolts HD 284 N-m (210 ft. lbs.)
Steering Damper with Wax Coat Frame
Frame Nut. .... 68 N-m (50 ft. lbs.)
Center Link Nut . . . .68 N-m (50 ft. lbs.)
Steering Damper with E-Coat Frame
Frame Nut. 88 N-m (65 ft. lbs.)
Center Link Nut .68 N-m (50 ft. lbs.)
Tie Rod
F i g . 3 Pitman Arm
Tie Rod Clamp 54 N-m (40 ft. lbs.)
INSTALLATION
(1) Position idler arm on the frame side rail and SPECIAL TOOLS
tighten to specification.
(2) Center steering gear to alignment marks and STEERING LINKAGE
install pitman arm.
(3) Install the lock washer and retaining nut on
the pitman shaft. Tighten the nut to 251 N-m (185 ft.
lbs.).
(4) Install center link to ball studs and tighten
retaining nuts to 88 N-m (65 ft. lbs.). Install new cot
ter pins.
(5) Install tie-rod ends into center link and tighten
the nuts to 88 N-m (65 ft. lbs.). Install new cotter
pins.
(6) Install steering damper to frame bracket and
center link (if equipped). Tighten nuts to 68 N-m (50
ft. lbs.). Install new cotter pins.
(7) Install tie-rod ends into steering knuckles and
tighten nuts to 88 N-m (65 ft. lbs.). Install new cotter
pins.
(8) Remove the supports and lower the vehicle to
the surface. Center steering wheel and adjust toe
(refer to the Alignment Specifications chart within
Group 2, Front Suspension).
NOTE: Position the clamp on the sleeve so retain

ing bolt is located on the bottom side of the sleeve. Remover Pitman C-4150A
19 - 22 STEERING
STEERING L I N K A G E — L I N K / C O I L SUSPENSION
INDEX
page page
GENERAL INFORMATION SPECIFICATIONS

FRAME COATINGS INFORMATION 22 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . 23
LINK/COIL—STEERING LINKAGE . . 22 SPECIAL TOOLS
REMOVAL AND INSTALLATION STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . 23
STEERING LINKAGE 22

frames:
| VEHICLE BUILD 11th POSITION FRAME

LOCATION VIN C H A R A C T E R COATING
Dodge City S Wax Coat TIE ROD TIE ROD

END
Saltillo Mexico G Wax Coat J9419-24
Lago Alberto
M Wax Coat Fig. 1 Link/Coil—Steering Linkage
j Mexico

frame attached components may vary depending on
LINK/COIL—STEERING LINKAGE
The steering linkage is comprised of a tie rod end,
tie rod, drag link, steering damper and pitman arm
(Fig. 1).

Fig. 2 Tie Rod End
STEERING LINKAGE
REMOVAL
NOTE: When servicing the steering linkage, use (1) Remove tie rod and steering damper from drag
care to avoid damaging ball stud seals. Use puller link.
C-3894-A to remove tie rod ends (Fig. 2). (2) Remove drag link tie-rod end from steering
knuckle and pitman arm.
(3) Mark the pitman arm and shaft positions for
installation reference. Remove the nut and washer
BR STEERING 19-23
from the pitman arm. Remove the pitman arm with SPECIFICATIONS
Puller C- 4150A.
(4) Remove tie rod from steering knuckle. TORQUE SPECIFICATIONS
INSTALLATION DESCRIPTION TORQUE
Pitman Arm
NOTE: When installing linkage tighten nuts to
proper torque, then align cotter pin slot by tighten Shaft 251 N-m (185 ft. lbs.)
ing nut if necessary. Drag Link
Ball Stud. 88 N-m (65 ft. lbs.)
(1) Align reference marks and install pitman arm. Tie Rod E n d
(2) Install the lock washer and retaining nut on Ball Stud. . . . . . . . . . . . . . 88 N-m (65 ft. lbs.)
the pitman shaft and tighten nut to 251 N-m (185 ft. Clamp 54 N-m (40 ft. lbs.)
lbs.). Tie Rod
(3) Install drag-link ball studs to steering knuckle Ball Stud. . . . 88 N-m (65 ft. lbs.)
and pitman arm. Install the retaining nuts and Steering Damper
tighten to 88 N-m (65 ft. lbs.). Install new cotter pins. Wax Coat Frame .68 N-m (50 ft. lbs.)
(4) Install tie-rod on steering knuckle and drag- E-Coat Frame 88 N-m (65 ft. lbs.)
link. Tighten the nuts to 88 N-m (65 ft. lbs.). Install Drag Link 68 N-m (50 ft. lbs.)
new cotter pins.
(5) Install steering damper on drag-link and SPECIAL TOOLS
tighten nut to 68 N-m (50 ft. lbs.). Install new cotter
pin. STEERING LINKAGE
(6) Remove the supports and lower the vehicle to
the surface. Center steering wheel and adjust toe,
refer to Group 2 Suspension.
(7) After adjustment tighten tie-rod adjustment
sleeve clamp bolts to 54 N-m (40 ft. lbs.).
NOTE: Position the clamp on the sleeve so retain

ing bolt is located on the bottom side of the sleeve.
Puller C-3894-A
Remover Pitman C-4150A

BR TRANSMISSION AND TRANSFER CASE 21 -1
TRANSMISSION AND TRANSFER CASE

CONTENTS
page page
AUTOMATIC TRANSMISSION—42RE . . . . . . . 102 NV3500 MANUAL TRANSMISSION 1

AUTOMATIC TRANSMISSION—46/47RE 246 NV4500 MANUAL TRANSMISSION 49
NV021 PTO ADAPTER 415
NV231 HD/NW241/N¥241 HD
TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . . . 381
N V 3 5 0 0 MANUAL T R A N S M I S S I O N
INDEX
page page
GENERAL INFORMATION TRANSMISSION—4WD 6

GENERAL INFORMATION 1 DISASSEMBLY AND ASSEMBLY
TRANSMISSION GEAR RATIOS 3 TRANSMISSION 8
TRANSMISSION LUBRICANT L E V E L AND CLEANING AND INSPECTION
CAPACITY 1 TRANSMISSION COMPONENTS 44
TRANSMISSION LUBRICANT 1 SPECIFICATIONS
DIAGNOSIS AND TESTING TORQUE 48
NV3500 TRANSMISSION . . . . . . . . . . . . . . . 3 SPECIAL T O O L S
REMOVAL AND INSTALLATION NV3500 . 48
TRANSMISSION—2WD 4
G E N E R A L INFORMATION TRANSMISSION LUBRICANT

Required lubricant for the NV3500 is Mopar Man
GENERAL INFORMATION ual Transmission Lubricant, P/N 4761526. This is the
The NV3500 is a medium-duty, 5-speed, constant only lubricant to be used in NV3500 transmissions.
mesh, fully synchronized manual transmission. Fifth No other lubricants are acceptable, or recommended.
gear is an overdrive range with a ratio of 0.0729:1.
The NV3500 is used with 3.9L and 5.2L engines and TRANSMISSION LUBRICANT LEWEL AND
is available in two and four-wheel drive configura CAPACITY ' •
tions. The correct transmission lubricant level is to the
The transmission gear case consists of two alumi bottom edge of the fill plug hole (Fig. 3).
num housings (Fig. 1). The clutch housing is not a The transmission must be level to obtain an accu
removable component. It is an integral part of the rate lubricant level check. A drive-on type of hoist is
transmission front housing. recommended for this purpose.
Roller bearings are used to support the transmis Lubricant capacity of the NV3500 is approximately
sion shafts in the two housings. The transmission 1.98 liters (4.2 pints). This represents the approxi
gears all rotate on caged type needle bearings. mate quantity needed to refill the transmission after
The NV3500 has a single shaft shift mechanism. a lubricant change or overhaul.
The three shift forks are all mounted on a one shift
shaft. The shaft is supported in the front and rear D R A I N AND FILL PLUG LOCATIONS
housings by bushings and one bearing. Internal shift The NV3500 fill and drain plugs are both located
components consist of the forks, shaft, shift lever in the front housing. The fill plug is at the passenger
socket, and detent components (Fig. 2).
BR NV3500 MANUAL TRANSMISSION 21 - 3
PLUNGER
J952M47
Fig. 2 NV3500 ift Mechanism

side of the housing. The drain plug is at the bottom TRANSMISSION GEAR RATIOS
of the housing (Fig. 3). Two versions of the N V 3 5 0 0 are now available. The
original wide ratio version introduced last year, has a
4.01 first gear and 2.318 second gear. The new close
ratio N V 3 5 0 0 has a 3.49 first gear and 2.16 second
gear.
WIDE RATIO VERSION
RANGE RATIO
FIRST 4.016:1
SECOND 2.318 1
THIRD = 1.401 1
FOURTH = 11
FIFTH = 0.729:1
REVERSE = 3.55:1
DIAGNOSIS A N D TESTING
NV3500 TRANSMISSION
LOW LUBRICANT LEVEL

A low transmission lubricant level is generally the
Fig. 3 Drain and Fill Plug Locations result of a leak, inadequate lubricant fill, or an incor
rect lubricant level check.
21 - 4 NV3500 MANUAL TRANSMISSION — — — — — — — BR
DIAGNOSIS A N D T E S T I N G (Continued)
CLOSE RATIO VERSION Worn or damaged synchro rings can cause gear
clash when shifting into any forward gear. I n some
RANGE RATIO new or rebuilt transmissions, new synchro rings may
FIRST 3.49:1
tend to stick slightly causing stiff and/or noisy shifts.
In most cases, this condition will decline as the rings
SECOND 2.16:1 wear in.
THIRD = 1.401:1
TRANSMISSION NOISE
FOURTH = 1:1
Most manual transmissions make some noise dur
FIFTH = 0.729:1 ing normal operation. Rotating gears can generate a
REVERSE 3.55:1 mild whine that may only be audible at extreme
speeds.
Leaks can occur at the mating surfaces of the Severe, obviously audible transmission noise is
housings, or from the front/rear seals. A suspected generally the result of a lubricant problem. Insuffi
leak could also be the result of an overfill condition. cient, improper, or contaminated lubricant can pro
Leaks at component mating surfaces will probably mote rapid wear of gears, synchros, shift rails, forks
be the result of inadequate sealer, gaps i n the sealer, and bearings. The overheating caused by a lubricant
incorrect bolt tightening, or use of a non-recom problem, can also lead to gear breakage.
mended sealer.
A leak at the front of the transmission will be from
either a loose or damaged, front bearing retainer or mmmmAL ^mm INSTALLATI®N
retainer seal. Lubricant may also drip from the
transmission clutch housing after extended opera TRANSMISSION—2WD
tion. I f the leak is severe, it will contaminate the
clutch disc causing slip, grab and chatter. REMOVAL
Transmissions filled from air or electrically pow (1) Disconnect battery negative cable.
ered lubricant containers can be under filled. This (2) Shift transmission into Neutral.
generally happens when the container delivery mech (3) Remove shift boot bezel screws and slide boot
anism is improperly calibrated. Always check the upward on shift lever extension.
lubricant level after filling to avoid an under fill con (4) Remove bolts attaching shift tower and lever
dition. assembly to rear case. Then remove shift tower and
A correct lubricant level check can only be shift lever extension as assembly (Fig. 4).
made when the vehicle is level; use a drive-on (5) I f isolator and plate came off during shift tower
hoist to ensure this. Also allow the lubricant to removal (Fig. 4), remove assembly from shift hous
settle for a minute or so before checking. These ing. Note that plate is one-way fit. Narrow side of
recommendations will ensure an accurate plate goes toward driver side of transmission.
check and avoid an under-or-overfill condition.
HARD SHIFTING
Hard shifting is usually caused by a low lubricant
level, improper or contaminated lubricants, transmis
sion component damage, clutch linkage malfunction,
or by a damaged clutch pressure plate or disc.
Substantial lubricant leaks can result in gear, shift
component, synchro and bearing damage. I f a leak
goes undetected for an extended period, the first indi
cations of a problem are usually hard shifting and
noise.
Incorrect or contaminated lubricants can also con
tribute to hard shifting. The consequence of using
non-recommended lubricants is * noise, excessive
wear, internal bind and hard shifting.
Improper clutch release is a frequent cause of hard Fig. 4 Shift Tower Removal
shifting. Incorrect adjustment or a worn, damaged
pressure plate or disc can cause incorrect release. I f (6) Raise vehicle on hoist.
the clutch problem is advanced, gear clash during (7) Remove crankshaft position sensor. Retain sen
shifts can result. sor attaching bolts.

(8) Remove skid plate, i f equipped. (21) Move transmission rearward until clear of
(9) Drain transmission lubricant i f transmission engine. Then lower jack and remove transmission
will be disassembled for service. from under vehicle.
(10) Mark propeller shaft and U-joint for installa (22) Remove transmission from jack and position
tion reference. Then disconnect and remove propeller transmission on workbench.
shaft. (23) I f transmission will be overhauled, remove
(11) Disconnect vehicle speed sensor wires. release bearing and fork from front housing.
(12) Disengage harness from clips on transmission (24) I f shift lever extension is press-on style and
housing. must be removed from shift lever, refer to following
(13) Support engine with adjustable jack stand. procedure:
(14) Remove nuts attaching rear mount to cross- (a) Obtain Remover/Installer Tool 6783.
member (Fig. 5). Then remove insulator from exten (b) Scribe mark position of extension on shank of
sion housing i f necessary. shift lever.
(15) Remove bolts and nuts attaching crossmember (c) Position notched, lower end of tool just under
to frame rails. Rotate crossmember diagonally and square shank of shift lever (Fig. 6).
remove crossmember. (d) Position tool upper jaws under flange on
(16) Disconnect exhaust pipes at manifold and at shift lever extension (Fig. 6).
converter or muffler connections as needed. Then (e) Tighten tool screw to pull . extension . off
remove Y-pipe, converter and tail pipe. square shank of shift lever.
(17) Remove slave cylinder attaching nuts and (f) Remove lever extension and tool.
remove cylinder from clutch housing.
(18) Remove starter motor. TRANSMISSION INSTALLATION
(19) Support transmission with transmission jack. (1) Make sure transmission front housing mount
Secure transmission to jack with safety chains. ing surface is clean before installation.
(20) Remove nuts/bolts attaching transmission (2) Lubricate release fork pivot ball, release fork,
front housing to engine. release bearing hub and transmission bearing
4X4
4X2 3500 MANUAL 4X2 4X4
3500 MANUAL 4500 ALL AUTOMATICS AUTOMATICS
J9509-126
Fig. 5 Transmission Rear Support Brackets

21 - 6 NV3500 MANUAL TRANSMISSION BR

(14) Install strut bolts/nuts, i f removed. Also
install oil filter i f removal was necessary.
(15) Connect vehicle speed sensor wires.
(16) Install and connect exhaust system. Align
exhaust components before tightening clamp and
bracket bolts and nuts. Be sure exhaust components
are clear of all chassis and driveline components.
(17) Align and install propeller shaft. Tighten
U-joint clamp bolts to 19 N-m (170 in. lbs.) torque.
(18) Verify that all linkage components, hoses and
electrical wires have been connected.
(19) Remove any remaining support stands and
lower vehicle.
(20) Install crankshaft position sensor.
(21) Connect battery negative cable.
(22) Apply Mopar Gasket Maker, or Loctite 518 to
mounting surface of shift tower, isolator plate, and
transmission case.
(23) Install isolator plate on shift tower, or rear
case. Then install shift tower and lever assembly.
Tighten shift tower bolts to 7-10 N-m (5-7 ft. lbs.)
torque. Note that isolator plate is one-way fit. Nar
row side goes toward driver side of transmission.
(24) I f shift lever extension was removed from
shift lever, reinstall with Tool 6783 as follows:
(a) Reposition upper jaw of Remover/Installer
Tool 6783 above flange on lever extension (Fig. 7).
Tool will now be used to press extension back onto
Fig. 6 Removing Shift Lever Extension With Tool 6788 shift lever.
(b) Tighten tool screw to press extension back
retainer surface with Mopar high temperature onto lever. Press extension to scribe mark made
grease. during removal.
(3) Mount transmission on jack. Secure transmis (c) Remove special tool.
sion to jack with safety chains. (25) Install shift boot and bezel.
(4) Lubricate transmission input shaft pilot hub
and splines with light coat of Mopar high tempera TRANSMISSION—4WD
ture grease.
(5) Align transmission input shaft with release REMOVAL
bearing and clutch disc. Then slide transmission into (1) Disconnect battery negative cable.
place on engine block. (2) Shift transmission into Neutral.
(6) Install and tighten transmission attaching (3) Remove screws attaching shift boot bezel and
bolts to 54-61 N-m (40-45 ft. lbs.) torque. Be sure slide boot upward on shift lever extension. Then
front housing is fully seated before tightening bolts. loosen extension locknut and unscrew extension from
Install front dust cover after all bolts are tightened. shift lever.
(7) Fill transmission with Mopar lubricant P/N (4) Remove bolts attaching shift tower and lever
4761526. Correct fill level is to bottom edge of fill assembly to rear case. Then remove shift tower and
plug hole. lever along with shift lever extension as an assembly.
(8) Connect backup light switch wires. (5) I f isolator and plate came off shift tower during
(9) Connect transmission harnesses to clips on removal, remove assembly from rear housing (Fig. 8).
case. Note that plate is one-way fit. Narrow side of plate
(10) Install crossmember. Tighten crossmem- goes toward driver side of transmission.
ber-to-frame bolts to 68 N-m (50 ft. lbs.) torque. (6) Remove crankshaft position sensor. Retain sen
(11) Tighten crossmember-to-transmission insula sor attaching bolts.
tor nuts to 68 N-m (50 ft. lbs.) torque. (7) Raise vehicle on hoist.
(12) Install slave cylinder. Tighten cylinder nuts to (8) Remove skid plate, i f equipped.
23 N-m (200 in. lbs.) torque. (9) Drain transmission lubricant i f transmission
(13) Remove jack used to support transmission. will be disassembled for service.
BR IW3500 MANUAL TRANSMISSION 21 - 7

(14) Remove nuts attaching transfer case to trans
mission adapter housing.
(15) Remove transfer case with aid of helper. Sup
port transfer case with transmission jack. Move
transfer case rearward, tilt it away from fixed (weld
ed) rear crossmember and work i t out from between
transmission and crossmember.
(16) Support engine with adjustable jack stand.
(17) Remove nuts and bolts attaching support
bracket and cushions to fixed crossmember.
(18) Remove nuts and bolts attaching removable
crossmember to frame rails. Rotate crossmember
diagonally to remove it.
(19) Disconnect exhaust pipes at manifold and at
converter or muffler connections as needed. Then
remove Y-pipe, converter and tail pipe.
(20) Remove slave cylinder attaching nuts and
remove cylinder from clutch housing. Move cylinder
aside for working clearance.
(21) Remove clutch housing dust cover.
(22) On some models, it may be necessary to
remove front axle struts and oil filter for access and
removal clearance. Remove these components i f nec
essary.
(23) Support transmission with transmission jack.
Secure transmission to jack with safety chains.
(24) Remove bolts attaching transmission clutch
housing to engine block.
Fig. 7 Installing Shift Lever Extension With Tool 6783 (25) Move transmission rearward until transmis
sion clutch housing is clear of engine. Then lower
jack and remove transmission from under vehicle.
(26) Remove transmission from jack and position
transmission on workbench.
(27) I f transmission will be disassembled for ser
vice, remove release bearing and fork.
(28) I f shift lever extension is press-on style and
must be removed from shift lever, refer to following
procedure:
(a) Obtain Remover/Installer Tool 6783.
(b) Scribe mark position of extension on shank of
shift lever.
(c) Position notched, lower end of tool just under
square shank of shift lever (Fig. 9).
(d) Position tool upper jaws under flange on
shift lever extension (Fig. 9).
(e) Tighten tool screw to pull extension off
Fig. 8 Shift Tower Removal square shank of shift lever.
(10) Mark propeller shafts and U-joints for instal (f) Remove lever extension and tool.
lation reference. Then disconnect and remove propel
ler shafts. TRANSMISSION INSTALLATION
(11) Disconnect vehicle speed sensor wires. (1) Make sure transmission front housing and
(12) Disconnect transfer case shift linkage at engine block contact surfaces are clean.
transfer case range lever. (2) Lubricate release fork pivot ball, release fork,
(13) Remove bolts attaching shift linkage bracket release bearing hub and transmission bearing
to transfer case and move linkage and bracket aside. retainer surface with Mopar high temperature
grease.
(15) Install transfer case. Align and position trans
fer case with transmission jack or aid of helper. Tilt
case upward and work into position on transmission
mounting studs.
(16) Install and tighten transfer case attaching
nuts to 47 N-m (35 ft. lbs.) torque.
(17) Install and connect transfer case shift linkage.
(18) Connect vehicle speed sensor harness wire to
sensor.
(19) Align and connect exhaust system compo
nents. Be sure exhaust components are clear of all
chassis and driveline components.
(20) Align and install front and rear propeller
shafts. Tighten U-joint clamp bolts to 19 N-m (170 in.
lbs.) torque.
(21) Verify that all linkage components, hoses and
electrical wires have been connected.
(22) Check transfer case fluid level. Add Mopar
Dexron I I , or ATF Plus i f necessary. Correct level is
to edge of fill plug hole. Be sure transfer case is level
before checking or adding fluid.
(23) Check and adjust transfer case shift linkage i f
necessary.
(24) Install transfer case skid plate, i f equipped.
(25) Fill transmission with Mopar lubricant, P/N
4761526. Correct fill level is to bottom edge of fill
plug hole.
(26) Install crankshaft position sensor.
Fig. 9 Removing Shift Lever Extension With Tooi 6783 (27) Remove any remaining support stands and
lower vehicle.
(3) Mount transmission on jack. Secure transmis (28) Connect battery negative cable.
sion to jack with safety chains. (29) Apply Mopar Gasket Maker, or Loctite 518 to
(4) Lubricate transmission input shaft pilot hub mounting surfaces of shift tower, isolator plate, and
and splines with light coat of Mopar high tempera lever mounting surface on transmission front housing.
ture grease. (30) Install isolator plate on shift tower, or rear
(5) Align transmission input shaft with release case. Then install shift tower and lever assembly.
bearing and clutch disc. Then slide clutch housing Tighten shift tower bolts to 7-10 N-m (5-7 ft. lbs.)
into place on engine block. torque. Note that isolator plate is one way fit. Nar
(6) Install and tighten transmission attaching bolts row side goes toward driver side of transmission.
to 54-61 N-m (40-45 ft. lbs.) torque. Be sure housing is (31) I f shift lever extension was removed from
fully seated before tightening bolts. I f equipped, install shift lever, reinstall with Tool 6783 as follows:
dust cover after tightening housing bolts. (a) Reposition upper jaw of Remover/Installer
(7) Fill transmission with Mopar lubricant, P/N Tool 6783 above flange on lever extension (Fig.
4761526. Correct fill level is to bottom edge of fill 10). Tool will now be used to press extension back
plug hole. onto shift lever.
(8) Connect backup light switch wires. (b) Tighten tool screw to press extension back
(9) Connect transmission harnesses and vent line onto lever. Press extension to scribe mark made
to retainer clips on housing. during removal.
(10) Install center crossmember. Tighten cross- (c) Remove special tool.
member-to-frame bolts to 67 N-m (50 ft. lbs.) torque. (32) Install shift boot and bezel.
(11) Tighten crossmember-to-support bracket nuts
to 54-61 N-m (40-45 ft. lbs.) torque.
(12) Install slave cylinder in transmission clutch DISASSEMBLY AND ASSEMBLY
housing. Tighten cylinder attaching nuts to 23 N-m
(200 in. lbs.) torque. TRANSMISSION ^
(13) Remove jack used to support transmission. The following disassemble and assemble procedures
(14) Install strut bolts/nuts, i f removed. require removing the transmission from the vehicle.
BR NW3500 MANUAL TRANSMISSION 21 - 9
(4) Remove shift tower bolts and remove tower and
lever assembly (Fig. 12). Use 8 mm socket to tower
remove bolts.
(5) If isolator and plate assembly came off shift tower
during removal, remove plate assembly from rear hous
ing (Fig. 12). Note that plate assembly is one-way fit.
Narrow side of plate goes toward driver side of trans
mission and rubber coated side faces upward.
Fig. 12 Shift Tower Removal

(6) Remove shift shaft lock bolt (Fig. 13). Bolt is
located at top of front housing just forward of shift
Fig. 10 Installing Shift Lever Extension With Tool 6783 tower. Bolt is a hex head, shoulder bolt that secures
FRONT HOUSING REMOVAL shift shaft bushing and lever. Use 13 mm socket to
(1) If necessary, temporarily reinstall isolator remove bolt.
plate and shift lever assembly. Then shift trans
13 mm
mission into Neutral.
(2) I f lubricant was not drained out of transmis
sion during removal, remove drain plug and drain
lubricant into container at this time.
(3) Remove backup light switch. Switch is located
on driver side of rear housing (Fig. 11).
Fig. 11 Backup Light Switch Location
Fig. 13 Shift Shaft Lock Bolt Removal


(7) Remove bolts attaching input shaft bearing (10) Remove snap ring that secures input shaft in
retainer in front housing (Fig. 14). Use 10 mm socket front bearing (Fig. 17).
to remove bolts.
INPUT SHAFT INPUT SHAFT
BEARING SNAP RING
RETAINER SE HEAVY DUTY
PUER TOOL)
Fig. 17 input Shaft Snap Ring Removal

(11) Remove shift shaft detent plug (Fig. 18). Use
crowfoot bar and hammer to lightly pry and tap plug
J9421-7 out of housing.
HAMMER
Fig. 14 input Shaft Bearing Retainer Bolt Removal
PRY
(8) Remove input shaft bearing retainer. Use pry tool TOOL
to carefully lift retainer and break sealer bead (Fig. 15).
TOOL
I
INPUT
SHAFT 11
BEARING J9421-11
RETAINER J9421-8
Fig. 18 Shift Shaft Detent Plug Removal
Fig. 15 Loosening Bearing Retainer Sealer Bead
(12) Remove shift shaft detent plunger and spring
(9) Remove bearing retainer from input shaft (Fig. (Fig. 19). Use pencil magnet to remove spring then
16). Note position of retainer lube channel for instal plunger.
lation reference.
SHAFT BEARING
BEARING RETAINER
Fig. 19 Detent Plunger And Spring Removal
INPUT /
SHAFT J9421-9
Fig. 16 Input Shaft Bearing Retainer Removal

(13) Remove bolts that attach front housing to rear (15) Remove input shaft bearing and countershaft
housing (Fig. 20). Three bolts at extreme rear of front bearing from front case (Fig. 22). Use hammer
housing are actually for the output shaft bear handle to tap input shaft bearing out of case. Coun
i n g retainer. I t is not necessary to remove a l l tershaft bearing can be removed by hand.
three bolts at this time. Leave at least one bolt INPUT
i n place u n t i l rear case is ready to be removed. SHAFT
BEARING
RETAINER
BOLTS
COUNTERSHAFT
FRONT
BEARING J9421-16
Fig. 22 Input Shaft And Countershaft Front Bearing

Location
(16) Note position of input shaft, shift shaft and
forks, and geartrain components in housing (Fig. 23).
SHIFT BUSHING REAR
SHAFT HOUSING
HOUSING
BOLTS
3-4
FORK
J9421-13
Fig. 20 Housing And Bearing Retainer Bolt

Locations
(14) Separate front housing from rear housing
(Fig. 21). Use plastic mallet to tap front housing off
alignment dowels.
REAR
HOUSING
REVERSE
OUTPUT IDLER AND
SHAFT SUPPORT
COUNTERSHAFT AND GEARS J9421-15
Fig. 23 Geartrain And Shift Component

Identification
PLASTIC
MALLET DOWELS (2)
Fig. 21 Front Housing Removal

DISASSEMBLY A N D ASSEMBLY ( C o n t i n u e d )
SHIFT SHAFT, SHIFT FORKS AMD REVERSE
IDLER SEGMENT REMOVAL
(1) Place shop towel over shaft lever and bushing
to contain lever detent ball and spring. Then rotate
lever and bushing upward out of shift forks and
catch ball and spring as they exit shaft lever (Fig.
24).
Fig. 25 Unseating Shift Socket Roll Pin With Tool

6858
(d) Remove 3-4 shift fork and 3-4 synchro sleeve
simultaneously. Use shop rag to catch struts, balls,
and springs as sleeve comes off hub.
(e) Slide shift shaft bushing off shaft lever. Then
rotate lever out of shift fork arms and catch ball
Fig. 24 Removing Shift Shaft Lever Detent Ball And and spring as lever clears notches.
Spring (f) Push shift shaft rearward, tap out pin (if
(2) Unseat roll pin that secures shift socket to needed) and pull shaft out of rear housing and
shift shaft with Special Tool 6858 as follows: shift forks. Use plastic mallet to assist shaft
(a) Position Tool 6858 on shift socket. Then cen removal.
ter tool over roll pin. Be sure tool legs are firmly (4) Drive out roll pin that secures shift bushing
seated on shift socket (Fig. 25). and lever to shift shaft (Fig. 26).
(b) Tilt socket toward passenger side of case.
This places roll pin at slight angle to avoid trap
ping pin between gear teeth.
(c) Tighten tool punch to press roll pin down
ward and out of shift socket (Fig. 25). Roll pin does
not have to come completely out of shift shaft; it
only has to clear shift socket.
(d) If roll pin accidentally becomes jammed
between gear teeth locking socket and shaft
in place, proceed to alternate disassembly
method in next step.
(3) If shift socket roll pin becomes jammed,
alternate disassembly method is as follows:
(a) Remove rear bearing retainer bolts.
(b) Remove reverse idler segment (but leave gear
in case).
(c) Remove input shaft, bearing, and 3-4 synchro Fig. 26 Removing Shift Shaft Lever And Bushing
ring. Roil Pin
BR NV3500 MANUAL TRANSMISSION 21 • 13

(5) Pull shift shaft out of rear housing, shift (8) Remove shift shaft (Fig. 30). Pull shaft straight
socket, fifth-reverse fork, and 1-2 fork (Fig. 27). Tap out of fork.
shift socket rearward with mallet to help remove
shaft. SHIFT o A
PLASTIC
MALLET
J9421-42
Fig. 80 Shift Shaft Removal

(9) Remove 3-4 fork. Rotate 3-4 fork around syn
Fig. 27 Pulling Shift Shaft Out Of Housing, Shift chro sleeve fork clears shift arms on 1-2 and fifth-re
Socket, And Shift Forks verse forks. Then remove 3-4 fork (Fig. 31).
(6) Remove shift- socket from rear housing (Fig.
3-4 1-2 AND
28).
FORK 5TH-REVERSE
SHAFT
Fig. 28 Shift Socket And Roll Pin

(7) Remove lever and bushing from shift shaft
(Fig. 29).
Fig. 31 Removing 3-4 Shift Fork
(10) Support geartrain and rear housing on Assem
bly Fixture Tool 6747 (with aid of helper) as follows:
(a) Adjust height of reverse idler pedestal rod to
18.42 cm (7-1/4 in.) Then position Adapters 6747-1
and 6747-2 on Assembly Fixture 6747.
(b) Slide fixture tool onto input shaft, counter

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9

To order the special service tools used and

NO PART OF THIS PUBLICATION MAY BE

Chrysler Corporation reserves the right to make changes in design or to

Litho in U.S.A. Copyright © 1995 Chrysler Corporation 20M0995

Service Manual Comment Forms (Rear of Manual)

GENERAL INFORMATION DISPLAY SYMBOLS 3

GENERAL INFORMATION To protect the consumer from theft and possible

Fig. 1 Vehicle Identification Number (VIN) Location

POSITION INTERPRETATION CODE = D E S C R I P T I O N

VEHICLE SAFETY CERTIFICATION LABEL BODY CODE PLATE

M Breakover Angle (Degrees] : 7.8/2 7 0 I 17.8/21.0 7-' •; :

1500/ 2500/ 3500/

VEHICLE EXTERIOR DIMENSIONS—CHASSIS C A B

WINDSHIELD WINDSHIELD WIPER

(©) ky > i ... i

FASTENER IDENTIFICATION INCH METRIC

THREAD IDENTIFICATION 5/16-18 M8 X 1.25

GENERAL INFORMATION (Continued)

bolt Markings and Torque - Metric

Commercial Steel Class

Bolt Markings and Torque Values - U.S. Customary

SAE Grade Number 5 8

Bolt Head Markings

Bolt Torque - Grade 5 Bolt Bolt Torque - Grade 8 Bolt

HOW TO DETERMINE BOLT STRENGTH

Mark Class Mark Class

Hexagon A— 4T Stud bolt

CONVERSION FORMULAS AND EQUIVALENT VALUES

Multiply By ToGaf Multiply By To Get

Inches Hg (60°F) x 3.377 Kilopascafs (kPa) kPa x 0.2961 = Inches Hg

Inches x 25.4 Millimeters (mm) mm x 0.03937 = Inches

mph x 1.6093 ss Kilometers/Hr. (Km/h) Km/h x 0.6214 = mph

COMMON METRIC EQUIVALENTS

in-lbs to N»m N»m to in-lbs

ft-lbs to N®m N®m to ft-lbs

LUBRICATION AND MAINTENANCE

GENERAL INFORMATION 1 MAINTENANCE SCHEDULES—LIGHT DUTY

GENERAL INFORMATION INTERNATIONAL SYMBOLS 1

GENERAL INFORMATION best engineered products for servicing Chrysler Cor­

PARTS AND LUBRICANT RECOMMENDATIONS Fig. 1 international Symbols

CLASSIFICATION OF LUBRICANTS progress to guttering and valve burning. A maximum

LUBRICANTS AND GREASES

3.9L. 19 L (20 qts.) N V 0 2 1 . . . . . . . . . . . . . . . . . . . . . . . . .2.1 L (4.6 pts.)

MANUAL TRANSMISSION Dana 60 (2WD) 3.0 L (6.3 pts.*)

GENERAL INFORMATION LIGHT DUTY SCHEDULE—B 5

G E N E R A L INFORMATION Once A Month

37,500 Miles (60 000 km) or at 30 months

102,000 Miles (163 000 km)

GENERAL INFORMATION MEDIUM DUTY SCHEDULE—B 9

GENERAL IMFORl^-L'^M Once A Month

18,000 Miles'(29 000 km) 51,000 Miles (82 000 km)

GENERAL INFORMATION INTRODUCTION . . . . . 12

GENERAL INFORMATION Once A Month

GENERAL INFORMATION SCHEDULE—B . 18

G E N E R A L INFORMATION At Each Oil Change

J U M P STARTING, TOWING AND HOISTING

SERVICE PROCEDURES J U M P STARTING PROCEDURE ... ...... 21

TO JUMP START A DISABLED VEHICLE:

CAUTION: If the cause of starting problem on dis­

Fig. 2 Jumper Cable Clamp Connections—Diesel

ground on disabled vehicle.

CAUTION: Do not use steering column lock to HOIST

GENERAL INFORMATION best engineered products for servicing Chrysler Cor

CAUTION: If the cause of starting problem on dis

CAUTION: Do not lift vehicle with a floor jack posi